Volvo S80 Recalls

The Volvo S80 has 36 recalls spanning the 1999–2016 production run, with the most serious being a driver's airbag inflator defect on 2001–2006 models where the inflator can rupture during deployment and send metal fragments into the cabin, causing serious injury or death.

The airbag inflator issue is particularly urgent for vehicles registered in high-humidity, high-heat states, where 2001–2003 models face an elevated risk of propellant degradation. On 2007–2016 models, a front seatbelt cable that attaches the belt to the seat frame can weaken and detach, leaving an occupant unrestrained in a crash. The 2012 model year has a wire harness under the front seats that can pull loose when the seat is adjusted, causing front and side airbags to misfire or fail entirely and the seatbelt pretensioner to not deploy. On 2016 models with the automatic stop-start system, the starter motor fuse can blow during stop-and-go driving, leaving the engine unable to restart in traffic.

The 2011–2013 model years have a transmission software error that can prevent downshifts while coasting, potentially stalling the engine. The 2011 model year also has a separate engine control module calibration that makes the fuel cut-off too sensitive, causing sudden stalls. On 2010 models, a software fault in the central electronic module can prevent the fuel pump from activating, which can also stall the engine. The 2008 model year has a cooling fan software error that can shut the fan down entirely, leading to rapid coolant temperature rise and possible engine failure, and a separate fuel system software issue with similar stall risk. A small number of 2008 S80s built with V8 engines have an engine mount bracket that can crack from insufficient clamping force. The 2007 model year has a power steering return hose that can burst from excess pressure, causing sudden loss of power steering assist, and a windshield wiper software fault that can leave wipers inoperative in rain.

Going further back, 2005 models have a positive battery cable that can chafe against the starter solenoid, short to ground, and produce smoke under the hood or prevent starting. The 2004 model year has front control arm studs that can lose tension and eventually separate from the spindle, causing a loss of steering control. On 2001 models, rear outboard seatbelt anchor bolts may have been undertightened, reducing restraint effectiveness in a crash, and a fuel pump issue in warm-climate states can cause fuel leaks that may ignite. The 1999 model year has multiple cooling fan issues where the fan can overheat and melt nearby electrical components, raising the risk of an engine compartment fire, as well as a front suspension ball joint that can develop excessive play and reduce steering control, and a throttle sensor issue that can trigger limp-home mode unnecessarily.