The 2004 Volvo S80 has 4 NHTSA recall campaigns affecting an estimated 448,518 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 63 complaints with NHTSA, most often about the fuel/propulsion system. Last updated July 5, 2026.
Recall campaigns
AIR BAGS21V7660002021-09-30259,383 affected
Defect
Volvo Car USA, LLC (Volvo Car) is recalling certain 2001-2006 S80 and 2001-2009 S60 vehicles. The driver's air bag inflator may explode during deployment, due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.
Consequence
An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.
Remedy
Dealers will replace the driver's air bag, free of charge. Owner notification letters were mailed November 29, 2021. Owners may contact Volvo Car customer service at 1-800-458-1552. Volvo's number for this recall is R10125.
EQUIPMENT10V5660002010-11-08416 affected
Defect
VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
Consequence
AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
Remedy
VOLVO ADVISES OWNERS TO PLEASE STOP USING THE GARMIN PORTABLE GPS DEVICE IMMEDIATELY, AND VISIT THE GARMIN WEBSITE TO DETERMINE IF THEIR UNIT IS AFFECTED. THE UNIT'S BATTERY WILL BE REPLACED WITH A NEW BATTERY AND A SPACER WILL BE INSERTED ON TOP OF THE BATTERY NEXT TO THE PCB. THIS SERVICE WILL BE PERFORMED FREE…
VOLVO IS RECALLING CERTAIN MODEL YEAR 2001-2005 S80, MODEL YEAR 2001-2004 V70, S60, XC70 AND MODEL YEAR 2003-2005 XC90 VEHICLES SOLD IN OR REGISTERED IN THE STATES OF ALABAMA, ARIZONA, ARKANSAS, CALIFORNIA, FLORIDA, GEORGIA, HAWAII, KENTUCKY, LOUISIANA, MISSISSIPPI, NEVADA, NEW MEXICO, NORTH CAROLINA, OKLAHOMA, SOUTH…
Consequence
IF THE CONDITION OCCURS VEHICLE OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL LEAK WHICH, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy
DEALERS WILL INSPECT THE FUEL PUMP INSTALLED IN THE VEHICLE, AND IF NECESSARY REPLACE THE FUEL PUMP WITH A PART OF A MODIFIED DESIGN. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JANUARY 15, 2010. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.
STEERING04V0290002004-01-1629,986 affected
Defect
ON CERTAIN PASSENGER VEHICLES, THE FRONT CONTROL ARMS MAY NOT HAVE BEEN MANUFACTURED CORRECTLY AND, AS A RESULT, THE STUD AND NUT THAT SECURE THE ARM TO THE SPINDLE MAY LOSE THEIR INITIAL AXIAL TENSION. UNDER CERTAIN DRIVING CONDITIONS, THE STEERING MAY BECOME LESS RESPONSIVE AND THE DRIVER MAY EXPERIENCE STEERING…
Consequence
THIS DRIVING CONDITION COULD EVENTUALLY LEAD TO SEPARATION BETWEEN THE FRONT CONTROL ARM AND THE SPINDLE, WHICH COULD RESULT IN A CRASH.
Remedy
DEALERS WILL INSTALL A NEW TYPE OF NUT. OWNER NOTIFICATION BEGAN ON FEBRUARY 16, 2004. OWNERS SHOULD CONTACT VOLVO CARS AT 1-800-458-1552.
Complaints by component
FUEL/PROPULSION SYSTEM
13
ELECTRICAL SYSTEM
5
SUSPENSION
5
1crashes
ENGINE AND ENGINE COOLING:ENGINE
4
ENGINE
3
POWER TRAIN
3
STEERING:LINKAGES
3
AIR BAGS
2
1crashes1injuries
EXTERIOR LIGHTING
2
SEAT BELTS
2
Total complaints63
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“Both of the key fobs I have are broken in that the key won't lock straight out or stay folded into the fob. The weight of the plastic fob alone frequently causes the key to twist backwards if the road is bumpy or uneven, which kills the engine and makes it extremely difficult to steer to safety…”
“On 11/17/2020 was driving to pick up decal for my car and I got a message that read a check airbags I didn't have any reading on my gages turn signal for right turn stay lit up not brinking just on , when I stopped and went in building to get decal came back to car started it my gages came back…”
“On 11/17/2020 was driving to pick up decal for my car and I got a message that read a check airbags I didn't have any reading on my gages turn signal for right turn stay lit up not brinking just on , when I stopped and went in building to get decal came back to car started it my gages came back…”
“After noticing a very acute smell of gas I took the vehicle in for inspection. The mechanic advise that I had a fuel leak in my 2004 volvo s 80 . Thats could have been a serious problem and that the car is not driveable in this condition.”
“Strong odor of gas outside of car. Recall on similiar cars but not in this area. Known issue by volvo but will not repair at no cost as it is outside of the 10 year extended warranty even though car does not have 150000 miles on. Fire hazard and should be for all cars of this year and make but…”
“Tl* the contact owns a 2004 volvo s80. On several occasions, the contact smelled fuel coming from the garage. Upon checking underneath the vehicle, the odor became stronger. The vehicle was taken to an independent mechanic who diagnosed that a fuel leak originated from the top of the fuel tank.…”
“Tl* the contact owns a 2004 volvo s80. The contact stated that he smelled fuel around the vehicle. Upon inspection, the contact noticed fuel had leaked out of the top of the fuel pump. The vehicle was not taken to a dealer. The vehicle was not diagnosed or repaired. The manufacturer was not made…”
“The car is putting forth a strong odor of gasoline. This was first noticed a couple of weeks ago but was put down to having just filled the tank. The problem has progressed to the point where you can smell gas 20 feet away from the car. We are not allowing our daughter to drive the car as it is an…”
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2004 Volvo S80 as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
contains ads and affiliate links. Full methodology.