Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 1996 Volvo 850 owners, lightly cleaned up (personal details are redacted by NHTSA).
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* 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.
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.
I'm reporting the fuel tank on our 1996 Volvo 850, VIN no. [redacted], calif. Lic. [redacted], mileage 93238. The fuel tank started leaking around March 27, 2004, upon my investigation I observed fuel leaking from the left side of the fuel tank at the seam behind the exhaust heatshield. On the left side of the fuel tank there are three (3) screws that fasten the heatshield to fuel tank. Removing the two (2) of the screws allowed me to further observe fuel leaking from molded screw retainer. The car has not been driven due to the dangers associated with this leaking fuel tank. I found on the NHTSA website a preliminary evaluation (pe03-003) was opened in January of 2003 but closed in June 2003. I also found an engineering analysis (ea03-008) has been opened and that NHTSA has been investigating this matter and has correspondence with Volvo concerning the other fifty four (54) incidences. …
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.
I noticed an odd noise which sounded like something rolling around in the back of the car, but nothing was. At time of state inspection, I alerted the inspectors. They felt something bumping from within the gas tank. I disassembled the floor coverings and inspection ports for fuel pump and gauge sender. I removed the gauge sender and looked into the tank and observed a plastic bowl-like object surrounding the fuel pump. I rocked the car and this bowl would slosh against the pump. This object appears to be a baffle to reduce sloshing around the pump. It would seem that it was intended to be glued in place, but has broken loose. I suppose that this would eventually damage pump or tank. A new tank will cost close to $400 which I will now order. Additional problem is intermittent failure of anti-lock brake/tracs system module.
Dt: caller received a recall letter but the consumer feels the dealer did not repair the problem. The manufacturers recall #140 and the NHTSA recall #04V368000 were to replace a heat shield. The caller said she feels the dealer did not do the recall because after the repair fuel leaked when she filled the tank. Neither the dealer nor the manufacturer have been contacted about the problem.
I own a 1996 Volvo 850 glt station wagon with 72,500 miles. The fuel tank cracked and developed a leak from the foward heat shield mount on the gas tank. There was raw gas leaking 3 to 4 inches from the exhaust pipe. The car has never been in a crash nor have we hit or run over anything that damaged the gas tank or heat shield. I replaced the gas tank and seals and have the old gas tank.
The fuel tank was observed to be leaking on 7/8/02 and this was confirmed by a technician on 7/9/02. The leakage occurs on one or more of the molded bosses upon which the heat shield is mounted. My suspicion is built-in stresses from the molded boss, perhaps not radiused properly where the boss joins the tank wall. It May also be a materials problem. The technician analyzing the problem said that they had seen the same failure on another 850 tank within the last 10 days. It is also possible that our extreme ambient heat May have caused a relatively inflexible heat shield to stress the assembly. It seems to be a critical safety problem, and I am disappointed that Volvo has not been willing to join in remedying this situation with us, after calling it to their attention.
On the night of May 13, 2003 a few hours after parking the car (1996 Volvo 850) in the garage the smell of gas became so strong it was overwhelming. Inspection of the car and floor of the garage revealed gas leaking in a fast steady drip from the fuel tank. The leaked gas had formed a small puddle on the floor. On the morning of May 14, I arranged to take the car in for service where it was confirmed that the fuel tank was indeed leaking from the seam. The car has not been repaired because the fuel tank was is on back order and is not expected to be available until June 1, 2001. The car is not drivable because of the leaking fuel. I believe this leak is the result of a defect in the original fuel tank as there is no apparent damage to the tank.
Under normal driving conditions started smelling fuel inside the car. It was determined to be a leak in the fuel tank. It was leaking from the seam of the fuel tank which is plastic. The location of the leak was next to were the exhaust pipe runs. This, in my opinion, could have resulted in a fire or explosion. I feel lucky. When the fuel tank was replaced I discovered it was redesigned, thus leading me to believe this was a know problem to Volvo. I was also required to replace the level sensor because it was not compatable with the new design. I am also going to be contacting Volvo about this situtation.
Related recalls
Fuel system, gasoline › Storage
On certain passenger vehicles, after prolonged exposure to heat, the fuel tank May seep or leak fuel at the points where the heat shield is attached.
Remedy: Volvo will inspect the fuel tank and replace it if any evidence of fuel seepage or leakage is found. All vehicles will receive new reinforcement bushings at the heat shield attachment points to prevent future leaks.
NHTSA investigations
Fuel tank leaks
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.
Fuel tank leaks
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.
Fuel System complaints in other 850 years
Frequently asked questions
How common are fuel system problems on the 1996 Volvo 850?
NHTSA has 26 complaints about the fuel & propulsion system of the 1996 Volvo 850, 14% of the model year's 192 complaints. The component named most often is storage › tank assembly (20 mentions).
Is there a recall for 1996 Volvo 850 fuel system problems?
Yes — NHTSA recall 04V-368 (storage, Jul 30, 2004). Recall repairs are free at authorized dealers.
At what mileage do 1996 Volvo 850 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 121,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.