1996 Volvo 850

THIS ENGINEERING ANALYSIS WAS OPENED ON JUNE 11, 2003, BASED ON 54 REPORTS OF FUEL TANK LEAKS.THE SUBJECT VEHICLES WERE 1993 THROUGH 1996 MODEL YEAR (MY) 850 VEHICLES. MODEL 850 WAS ALSO PRODUCED IN MY 1997 AND WAS INCLUDED IN THIS INVESTIGATION. ANALYSIS OF THE DATA REVEALS TWO DISTINCT ISSUES. FIRST, THE 1994 THROUGH 1997 MY VEHICLES STAND OUT BY ACCOUNTING FOR 95 PERCENT OF THE REPORTED LEAKS.THESE VEHICLES SHARE THE SAME FUEL TANK DESIGN (PN 9142618). THE 1993 MY VEHICLE USES A DIFFERENT FUEL TANK DESIGN (PN 9141101).SECONDLY, THE FAILURES OCCURRED PREDOMINANTLY IN HOT CLIMATES, E.G., CALIFORNIA, ARIZONA, TEXAS, FLORIDA, GEORGIA, LOUISIANA, ETC.TESTING OF FUEL TANKS FROM CONSUMER VEHICLES AT THE VEHICLE RESEARCH AND TEST CENTER CONFIRMED LEAKS THROUGH CRACKS IN THE FUEL TANK WALL AT A HEAT SHIELD MOUNTING ATTACHMENT IN THE 1994 THROUGH 1997 MY FUEL TANKS (PN9142618). DETAILS OF THE TESTS ARE AVAILABLE IN TEST REPORT VRTC-DCD3060.VOLVO WILL CONDUCT A SAFETY RECALL ON ALL MY 1994 THROUGH 1997 VEHICLES ORIGINALLY SOLD OR REGISTERED IN THE FOLLOWING 17 HOT STATES: CA, AZ, NM, TX, LA, MS, AL, GA, SC, FL, NC, TN, AR, OK, UT, NV, AND HI.ALL 1994 THROUGH 1997 MY VEHICLES IN ALL OTHER STATES WILL BE REMEDIED UNDER A SERVICE CAMPAIGN.THE REMEDY FOR BOTH THE RECALL AND SERVICE CAMPAIGN IS TO INSTALL A NEW BUSHING AT EACH HEAT SHIELD ATTACHMENT POINT (3 PER TANK).ALSO, ALL TANKS (VEHICLES IN ALL STATES) WILL BE INSPECTED FOR FUEL SEEPAGE AT THE HEAT SHIELD ATTACHMENT POINTS AND VOLVO WILL REPLACE ANY TANK SHOWING SIGNS OF FUEL SEEPAGE.THE NEW BUSHINGS WILL PREVENT HEAT SHIELD STRESSES FROM BEING TRANSFERRED TO THE THREE HEAT SHIELD MOUNTING ATTACHMENTS ON THE FUEL TANK.THE SAFETY RECALL IS FILED UNDER NHTSA SAFETY RECALL NUMBER 04V368.THIS INVESTIGATION IS CLOSED.

THE OFFICE OF DEFECTS INVESTIGATION OPENED THISINVESTIGATION ON JANUARY 16, 2003.THE BASIS FOR OPENING THE INVESTIGATION WAS 15 CONSUMER REPORTS ALLEGING GASOLINE LEAKING FROM THE FUEL STORAGE TANK.VOLVO PROVIDED 43 ADDITIONAL REPORTS IN ITS RESPONSE TO THE PRELIMINARY EVALUATION, 4 OF WHICH WERE DUPLICATES OF THE 15 ODI REPORTS. THIS INVESTIGATION HAS BEEN UPGRADED FOR FURTHER STUDY.

VOLVO IS CONDUCTING A SAFETY RECALL BASED ON ITS ANALYSIS OF COMPLAINTS AND TECHNICAL INFORMATION DEVELOPED DURING ITS INVESTIGATION.VOLVO'SSURVEY OF VEHICLES ROUTINELY BROUGHT IN FOR MAINTENANCE AT EAST-COAST DEALERSHIPS PRODUCED EVIDENCE THAT BARE METAL WIRES (THAT PROVIDE SUPPORT FOR THE SEAT BOTTOM) CAN CONTACT THE THERMOSTAT AND ELECTRICAL WIRESIN OR BENEATH THE SEAT CUSHION.THIS CAN RESULT IN AN ELECTRICAL SHORT.VOLVO CONFIRMED IN TESTING THAT IF SUCH A CONDITION IS PRESENT, THE SHORT TO THE WIRE SEAT SUPPORT COULD CAUSE BURNING OF THE SEAT CUSHION WITHOUT ACTIVATING (OPENING) THE SEAT HEATER FUSE.VOLVO WILL REPLACE THE ENTIRE THERMOSTAT ASSEMBLY WITH AN ELECTRONIC TIMER DELAY UNIT.

MY FUEL TANK STARTED LEAKING EXACTLY AS THE RECALL # 04V368000 DESCRIBES, WHERE THE HEAT SHIELD CONNECTS TO THE FUEL TANK. I FILLED UP, DROVE 3 MILES HOME, PARKED IN MY DRIVEWAY, AND SMELLED GAS, BUT DID NOT *SEE* ANYTHING AT THAT TIME. IT LOST 6 GALLONS OF FUEN IN ABOUT 3 HOURS HOURS. VOLVO SAYS THIS RECALL DOES NOT PERTAIN TO MY VEHICLE, BECAUSE THEY DO IT BY SPECIFIC VIN NUMBERS, BUT WOULD NOT SAY ANYTHING FURTHER. IT IS IN MY LOCAL SHOP PARKING LOT, I WAS UNABLE TO PHOTOGRAPH THE LEAK AS I AM DISABLED AND COULD NOT CLIMB UNDER THE CAR.

NHTSA ID

11114531

Incident

Jul 28, 2018

Mileage

231,000 mi

THIS VEHICLE HAS A LEAK AT A SEAM OF THE GAS TANK. CHEN ENGINE LIGHT IS ON WITH OBO 11 CODE P0455 EVAPORATIVE EMISSION SYSTEM LEAK DETECTED LARGE LEAK NO FLOW. A CERTIFIED VOLVO REPAIR FACILITY HAS VERIFIED CRACK AT SEAM FROM GAS TANK. *TR

NHTSA ID

10714113

Incident

May 1, 2015

Mileage

169,000 mi

TL* THE CONTACT OWNS FOUR COOPER ZEON SPT TIRES, SIZE 205 55 R16. THE CONTACT WAS ROTATING THE TIRES, WHEN HE NOTICED THE FRONT DRIVERS SIDE TIRE WAS BALD. THE TIRES WERE INSPECTED AND THE CONTACT WAS ADVISED THAT THE TIRES WERE DOWN TO THE WEAR BAR. THE TIRES WERE NOT REPLACED. THE TIRE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE CURRENT VEHICLE MILEAGE WAS 100,00 AND THE APPROXIMATE TIRE MILEAGE WAS 8,000.

NHTSA ID

10548236

Incident

Oct 18, 2011

Mileage

97,000 mi

RUNAWAY ACCELERATOR ? ON ENTERING INTERSTATE, I QUICKLY REALIZED THAT THE ACCELERATOR WAS LOCKED INTO THE FLOORED POSITION. I HAD A RUNAWAY SITUATION WITH TRAFFIC. I WAS UNABLE TO SLOW THE CAR OR RELEASE THE ACCELERATOR. FORTUNATELY, I HAD THE KNOWLEDGE AND SENSE TO SLOW THE CAR. PUMPING THE BRAKES DID NOT HELP. I MANAGED TO HOLD THE BRAKES WHILE DOWNSHIFTING INTO THE LOW AND THEN LOWEST GEAR IN AUTOMATIC TRANSMISSION. I MANAGED TO NEGOTIATE THE CAR TOWARD THE SHOULDER AND EVENTUALLY THREW THE TRANSMISSION INTO THE PARK GEAR. THE CAR JOLTED, THEN STOPPED. THIS WAS A LIFE THREATENING SITUATION FOR ME AND OTHERS ON THE ROAD. *TT

NHTSA ID

10459228

Incident

May 20, 2012

Mileage

185,500 mi

I OWN A 1996 VOLVO 850 TURBO. RECENTLY THE GAS TANK BEGAN TO LEAK AT THE SEAM ON THE DRIVER SIDE NEXT TO EXHAUST HEAT SHIELD I CALLED VOLVO AND THEY TOLD ME THAT MY FOR MY VIN # THERE IS NO RECALL; ON THE INTERNET THERE IS A RECALL FOR THE SAME VEHICLE GAS STORAGE ISSUES. EXACTLY ON THE SAME SIDE SAME PROBLEM, BUT SINCE MY VIN # DOES NOT COINCIDE WITH THEIR RECALL, I HAVE TO PAY FOR IT. I DON'T THINK THAT IT IS FAIR, THAT JUST BECAUSE MY VIN # IS DIFFERENT FROM THE RECALL, NUMBERS, IT STILL HAS THE SAME PROBLEM AS THE MODELS THEY ARE RECALLING. IF THEY ARE RECALLING A CERTAIN MODEL IN THIS CASE THE 850 MODEL FOR SPECIFIC DEFECTS, WHAT DIFFERENCE DOES IT MAKE WHAT VIN # IT IS, IF IT HAS THE SAME PROBLEM ON THE RECALL. AND A SAFETY ISSUE. IF YOU CAN HELP WITH THIS, PLEASE LET ME KNOW WHAT I CAN DO. BECAUSE THE VOLVO AGENT WAS NOT VERY HELPFUL AND RUDE. BOTTOM LINE WAS TO BAD FOR YOU. *TR

NHTSA ID

10420743

Incident

Jul 16, 2011

Mileage

170,000 mi

ON FEBRUARY 9, 2008 I PURCHASED AT MAVIS TIRE FOUR (4) NEW COOPER ZEON TIRES WITH A RATING OF 400 AAA. IN APPROXIMATELY SIX THOUSAND (6,000) I FIND ONE PAIR COMPLETELY WORN WHILE THE OTHER SET FULL THREAD. I CALLED MAVIS TIRE AND SPOKE WITH STU WHO SAID HE IS THE MANAGER. HE SUGGESTED I COME INTO THE TIRE SHOP SO HE MAY INSPECT THE TIRES. ON MARCH 2011, I DROVE TO LONG BEACH, LONG ISLAND WHERE THE SHOP IS LOCATED. STU INSPECTED THE TIRES AND AGREED WITH ME THAT SOMETHING WAS DEFECTIVE WITH THE TWO TIRES IN QUESTION. STU THEN TOLD ME HE WOULD CHECK WITH HIS SUPERVISOR AND GET BACK TO ME. STU THEN CALLED ME AND TOLD ME TO PLACE A CLAIM WITH COOPER TIRES. I WAS ALSO TOLD THEIR PHONE NUMBER WAS AT THEIR WEB SITE. I COULD NOT FIND A NUMBER TO CALL BUT DID FIND AN PLACE TO SUBMIT AN EMAIL. I EXPLAINED THE SITUATION AND THIS WAS THE RESPONSE: ?COOPER PRODUCTS ARE BACKED BY A WORKMANSHIP AND MATERIALS WARRANTY THAT OUR INDEPENDENT TIRE DEALERS ADMINISTER ON A REGULAR BASIS. ANY TIRE THAT IS DEEMED TO HAVE AN ELIGIBLE ADJUSTABLE CONDITION AS DETERMINED BY ONE OF OUR INDEPENDENT TIRE DEALERS SHALL BE PROCESSED ACCORDING TO THE TERMS OF THE COOPER WARRANTY PROGRAM. OUR INDEPENDENT TIRE DEALERS MAKE THE DETERMINATION ON WHAT QUALIFIES AS AN ELIGIBLE ADJUSTABLE CONDITION, AND HANDLE ALL WARRANTY RETURNS. WE OFFER MILEAGE WARRANTIES ON SEVERAL TIRE MODELS. WE DO NOT OFFER MILEAGE ON PERFORMANCE TIRES, WHICH INCLUDES ALL ZEON MODELS. [XXX] CONSUMER QUALITY SYSTEMS COOPER TIRE & RUBBER CO. 800-854-6288 M-F 8-5 EST.? I THEN PLACE A CALL TO STU AND ADVISED HIM OF THE SITUATION. I NEVER MADE A CLAIM ABOUT MILEAGE WEAR. THERE IS APPROXIMATELY 6,000 MILES ON THE TIRES IN QUESTION. THE MUST BE A DEFECT IN THESE TIRES. A REPRESENTATIVE FROM MAVIS TIRE [XXX] HAS BEEN IN CONTACT WITH ME. THERE HAS NOT BEEN ANY CONTACT IN OVER A WEEK SO IT IS TIME OR ME TO ADDRESS THE SITUATION. IF I WAS NOT SO FASTEDIOUS IN CHECKING MY VEHICLE I NEVER WOULD HAVE KNOWN (OR EXPECTED) THESE TIRES TO FAIL. *TR

NHTSA ID

10394382

Incident

Feb 26, 2011

Mileage

96,000 mi

TL* THE CONTACT OWNS A 1996 VOLVO 850. THE CONTACT STATED THAT WHEN TRAVELING OVER DIFFERENT DEVIATIONS ON THE ROAD, THE REAR END OF THE VEHICLE WOULD FISH TAIL. IN ADDITION, THE VEHICLE WOULD SPORADICALLY STALL WITHOUT WARNING. THE CONTACT WOULD HAVE TO RECEIVE A JUMP START IN ORDER TO RESTART THE VEHICLE EACH TIME THE VEHICLE STALLED. THE DEALER WAS NOTIFIED WHO WAS UNABLE TO DUPLICATE THE FAILURE. THE CONTACT TRIED CONTACTING THE MANUFACTURER VIA WEB MAIL BUT TO NO AVAIL. THE VEHICLE WAS NOT REPAIRED OR DIAGNOSED. THE CURRENT MILEAGE WAS 151,805 AND THE FAILURE MILEAGE WAS APPROXIMATELY 150,805. UPDATED 03/02/11 *BF THE CONSUMER STATED THE TRUNK LID LATCH WAS FAULTY. THE WINDSHIELD WIPER ARM FLEW OFF WHILE DRIVING IN THE RAIN. UPDATED 04/29/11

NHTSA ID

10376732

Incident

Dec 1, 2010

Mileage

150,805 mi

I HAVE A 1996 VOLVO 850 TURBO STATION WAGON. IT HAS ONLY 41,000 MILES BUT THE ABS LIGHT WOULD COME ON AND OFF. I AM TOLD THIS IS A COMMON PROBLEM FOR THE CAR. VOLVO CLAIMS IT IS ONE OF THE SAFEST CAR ON THE ROAD AND QUITE RELIABLE. I DISAGREE. PLS. ASK VOLVO TO ISSUE A RECALL AS THIS IS ANNOYING AND COULD PROVE TO BE DANGEROUS. *TR

NHTSA ID

10269136

Incident

Aug 1, 2006

Mileage

41,000 mi

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