The 2001 S80 was Volvo's first front-wheel-drive flagship, and it shows—particularly in transmission durability and electronic complexity. The 2.9L I6 is the reliable choice; the 4.4L V8 and turbo five-cylinder bring expensive headaches.
Automatic Transmission Failure (GM 4T65 in I6, Aisin AW55-50SN in others)
Common · high severity
Typical onset: 90,000-140,000 mi
Symptoms: Harsh or delayed shifts, especially 2-3 upshift, Whining or buzzing noise from transmission area, Transmission slipping under load or refusing to engage, Burned ATF smell or dark red/brown fluid on dipstick
Fix: The I6 uses a GM 4T65 that grenades clutch packs; turbo and V8 use Aisin AW55 that suffers valve body/solenoid failures. Replacement or rebuild runs 18-24 labor hours. Many opt for used transmissions due to rebuild costs approaching vehicle value.
Estimated cost: $2,800-5,500
Upper Engine Mount (Torque Mount) Collapse
Common · medium severity
Typical onset: 70,000-110,000 mi
Symptoms: Heavy clunk when shifting from Park to Drive or Reverse, Vibration at idle that worsens with A/C on, Visible engine rocking when revving in Park, Transmission linkage feels vague or notchy
Fix: The fluid-filled upper engine mount separates internally, letting the transverse engine rock excessively and stress other mounts and axles. Replacement takes 2-3 hours but requires supporting the engine from below or above. OE Volvo part strongly recommended.
Estimated cost: $400-700
PCV System Oil Sludge and Turbo Failure (2.5T)
Common · high severity
Typical onset: 80,000-130,000 mi
Symptoms: Blue smoke on startup or acceleration, Excessive oil consumption (quart per 1,000 miles or worse), Whistling or squealing from turbocharger area, Check engine light with low boost or misfire codes
Fix: Volvo's PCV system on the turbo five-cylinder clogs easily, causing crankcase pressure that blows seals and cooks oil into sludge. This starves the turbo and eventually the main bearings. Full repair includes PCV system overhaul, turbo replacement, and often crankshaft/bearing work if caught late. Turbo alone is 6-8 hours; engine rebuild adds 25-35 hours.
Symptoms: Sudden limp mode with reduced power, Check engine light with throttle position or idle control codes, Idle surging or stalling when coming to a stop, Throttle pedal unresponsive or sticky response
Fix: The ETM (throttle body with integrated control module) fails electronically or mechanically. Volvo requires replacement as a unit; aftermarket rebuilds exist but are hit-or-miss. Replacement is 1.5-2 hours but part cost dominates.
Estimated cost: $800-1,400
Front Lower Control Arm Bushings and Ball Joints
Common · medium severity
Typical onset: 80,000-120,000 mi
Symptoms: Clunking over bumps or when turning, Steering wander or vague on-center feel, Inner tire edge wear, Vibration at highway speeds that changes with steering input
Fix: Volvo pressed non-serviceable bushings and ball joints into the aluminum lower control arms. When they wear, you replace the entire arm assembly per side. Both sides typically need replacement together. 3-4 hours for both sides including alignment.
Estimated cost: $900-1,500
Fuel Pump Failure (in-tank)
Occasional · high severity
Typical onset: 100,000-150,000 mi
Symptoms: No-start condition with cranking but no fire, Intermittent stalling, especially when fuel tank below 1/4, Whining or buzzing from rear seat area, Stumbling or hesitation under hard acceleration
Fix: The in-tank pump assembly fails due to age and contamination. Replacement requires dropping the fuel tank (6-8 hours) or cutting an access panel in the trunk floor (shade-tree method, not recommended for insurance reasons). Recall 04V211000 addressed some units but many fall outside scope.
Estimated cost: $800-1,300
Cooling System Leaks (expansion tank, radiator, hoses)
Common · medium severity
Typical onset: 90,000-140,000 mi
Symptoms: Coolant smell from engine bay, Visible coolant drips or puddles under car, Low coolant warning light or message, Overheating in traffic or at idle
Fix: Plastic expansion tank cracks at mounting tabs or seams; upper radiator and heater hoses become brittle. Addressing the whole system (tank, hoses, radiator if needed) takes 4-6 hours. Do it all at once to avoid repeat teardown.
Estimated cost: $600-1,200
Owner tips
Change ATF every 30k miles with genuine Volvo-spec fluid—these transmissions are intolerant of extended intervals
Replace PCV system components (breather box, flame trap) every 60k on turbo models to prevent sludge
Use synthetic oil and change every 5k miles maximum—the turbo and tight engine tolerances don't forgive neglect
Budget for an independent Volvo specialist; generic shops often misdiagnose the ETM and transmission issues
Buy the 2.9L I6 if you must, budget $2k/year for repairs, and walk away from any turbo or V8 unless you enjoy expensive gambles.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE · 21V766000
2021-09-30
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.
AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE · 20V681000
2020-11-04
Volvo Car USA LLC (Volvo Car) is recalling certain 2001-2003 S80 and S60 vehicles sold or ever registered in Alabama, Arkansas, Florida, Georgia, Hawaii, Louisiana, Mississippi, North Carolina, Oklahoma, South Carolina, Tennessee, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands. The driver side frontal air bag inflator may rupture, sending metal fragments into the passage compartment, when the driver side air bag is deployed.
Consequence: Metal fragments can strike vehicle occupants increasing the risk of serious injury or death.
Remedy: Volvo Car will notify owners, and dealers will replace the driver side air bag module, free of charge. The recall began April 20, 2021. Owners may contact Volvo Car customer service at 1-800-458-1552. Volvo Car's number for this recall is R10058.
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 OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 18, 2010. OWNERS MAY CONTACT GARMIN AT 866-957-1981 OR VISIT GARMIN'S WEBSITE AT WWW.GARMIN.COM/NUVIBATTERYPCBRECALL.
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 CAROLINA, TENNESSEE, TEXAS, UTAH, VIRGINIA AND THE U.S. TERRITORIES. WHEN EXPOSED TO CERTAIN ENVIRONMENTAL CONDITIONS (HOT CLIMATE AND TEMPERATURE CYCLING) OVER TIME AND IN COMBINATION WITH VARYING FUEL QUALITY, THE FUEL PUMP CAN DEVELOP CRACKS IN THE FUEL PUMP FLANGE.
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.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER · 07E023000
2007-03-29
CERTAIN CARDONE MASTER CYLINDERS WITH PART NUMBERS 10-2925, 10-2987, 10-2987MZA, 10-3083, 11-3015, 11-3042, 11-3044, 11-3045, 11-3047, 11-3064, AND 11-3156, AND WITH DATE CODES LOWER THAN DCA7078 SOLD AS REPLACEMENT EQUIPMENT FOR USE ON THE VEHICLES LISTED ABOVE. THE SEAL ON MASTER CYLINDER CAN FAIL AND LEAK BRAKE FLUID.
Consequence: LOSS OF BRAKE FLUID CAN RESULT IN POOR BRAKING PERFORMANCE, POSSIBLY RESULTING IN A VEHICLE CRASH.
Remedy: CARDONE WILL NOTIFY OWNERS AND OFFER TO REPURCHASE ANY DEFECTIVE MASTER CYLINDERS. THE RECALL BEGAN DURING APRIL 2007. OWNERS CAN CONTACT CARDONE AT 1-800-777-4780.
VEHICLE SPEED CONTROL · 06V441000
2006-11-15 · EA05021
ON CERTAIN PASSENGER VEHICLES, A COMBINATION OF THROTTLE POSITIONING SENSOR IRREGULARITIES, A DIRTY THROTTLE HOUSING, AND/OR INEFFICIENT SOFTWARE CALIBRATION MAY CAUSE A WARNING LAMP TO LIGHT AND THE SUBSEQUENT ONSET OF LIMP HOME MODES.
Consequence: THIS RESULTED IN A HIGH NUMBER OF VEHICLES GOING INTO THE LIMP HOME MODE WITHOUT NEED.
Remedy: DEALERS WILL INSTALL THE CURRENT SOFTWARE UPGRADE ONTO THE INVOLVED VEHICLES. THE RECALL BEGAN ON DECEMBER 29, 2006. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.
ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN · 04V451000
2004-09-13
ON CERTAIN PASSENGER AND SPORT UTILITY VEHICLES, UNDER CERTAIN OPERATING CONDITIONS, SOME ELECTRIC COOLING FANS MAY OVERHEAT POTENTIALLY CAUSING HEAT DAMAGE AND, IN RARE INSTANCES, A FIRE IN THE ENGINE COMPARTMENT.
Consequence: A FIRE IN THE ENGINE COMPARTMENT COULD OCCUR.
Remedy: DEALERS WILL REPLACE THE COOLING FAN. THE RECALL BEGAN ON NOVEMBER 29, 2004. CUSTOMERS SHOULD CONTACT VOLVO CARS AT 1-800-458-1552.
SEAT BELTS:FRONT:ANCHORAGE · 01V100000
2001-03-26
VEHICLE DESCRIPTION: SEDANS AND WAGONS. THE REAR OUTBOARD SEAT BELT ANCHORAGE BOLTS MAY HAVE BEEN INCORRECTLY TIGHTENED.
Consequence: IN THE EVENT OF A CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED, INCREASING THE RISK OF INJURY.
Remedy: DEALERS WILL INSPECT THE ANCHORAGE BOLTS AND TIGHTEN TO THE CORRECT TORQUE LEVEL. OWNER NOTIFICATION BEGAN MAY 7, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT VOLVO AT 1-800-458-1552.
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