Volvo · Known Issues

2004 Volvo S80 Problems: 3 Known Issues

2004 model year · 126+ owner reports · Updated September 2026

According to Au7o's analysis of 126+ owner reports, the 2004 Volvo S80 has 3 documented known issues, with 3 rated critical. The most serious are Fuel Pump Flange Cracking and Fuel Leaks ($450-$1,000 repair), Front Upper Ball Joint and Control Arm Separation ($500-$1,400 repair) and Driver Airbag Inflator Rupture Risk. Across all issues with published estimates, repair costs range from $450 to $1,400. DIY maintenance guides at au7o.io.

Frequently Asked Questions

What are the most common Volvo S80 problems?

According to Au7o's analysis of 126+ owner reports, the 2004 Volvo S80 has 3 documented issues. The most frequently reported are: Fuel Pump Flange Cracking and Fuel Leaks, Front Upper Ball Joint and Control Arm Separation, Driver Airbag Inflator Rupture Risk. Of these, 3 are rated critical and should be addressed promptly.

Is the Volvo S80 reliable?

The 2004 Volvo S80 has 3 known issues documented across 126+ owner reports. 3 issues are rated critical: Fuel Pump Flange Cracking and Fuel Leaks and Front Upper Ball Joint and Control Arm Separation and Driver Airbag Inflator Rupture Risk. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Volvo S80 problems?

Repair costs for known Volvo S80 issues range from $450 to $1,400, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Fuel Pump Flange Cracking and Fuel Leaks, typically costs $450-$1,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2000-2005 Volvo S80 Fuel Pump Flange Cracking and Fuel Leaks?

Another well-documented issue is fuel leakage from the fuel pump area, often accompanied by a strong raw-fuel smell inside the cabin and around the rear seat area. Complaints describe visible wetness or dripping fuel, sudden fuel gauge drop, and concern about fire risk. This patt… Repairs typically run $450-$1,000. Severity: high.

What is the 2000-2004 Volvo S80 Front Upper Ball Joint and Control Arm Separation?

The S80 shows a clear pattern of front suspension failures involving looseness or separation at the upper ball joint/control arm connection. Complaints describe loud bangs, sudden steering loss, wheel collapse, and even tire detachment. This is strongly supported by recall 00V238… Repairs typically run $500-$1,400. Severity: high.

What is the 2001-2006 Volvo S80 Driver Airbag Inflator Rupture Risk?

For 2001-2006 S80 models, Volvo issued recalls for the driver frontal airbag inflator due to propellant degradation over time. In a crash, the inflator can rupture during deployment and send metal fragments toward occupants, creating a severe injury risk. This is a recall-driven… Severity: high.

2004 Volvo S80 Problems: 3 Known Issues

All 3 Known Issues

2000-2005 Volvo S80: Fuel Pump Flange Cracking and Fuel Leaks#

Common Symptoms

How to Fix

Owner tips & cautions

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2000-2004 Volvo S80: Front Upper Ball Joint and Control Arm Separation#

Common Symptoms

How to Fix

Owner tips & cautions

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2001-2006 Volvo S80: Driver Airbag Inflator Rupture Risk#

Common Symptoms

How to Fix

Owner tips & cautions

Research This Issue

Other Volvo Models

Frequently Asked Questions

What are the most common Volvo S80 problems?

Is the Volvo S80 reliable?

How much does it cost to fix common Volvo S80 problems?

What is the 2000-2005 Volvo S80 Fuel Pump Flange Cracking and Fuel Leaks?

What is the 2000-2004 Volvo S80 Front Upper Ball Joint and Control Arm Separation?

What is the 2001-2006 Volvo S80 Driver Airbag Inflator Rupture Risk?