I have had my 850T5R for over 8 years. During this time I have put up with the Pirelli tire debacle, non-working odometer, various and other asundry eletronic problems, one taking the dealer up to a year to diagnose, and all the squeeks, rattles and foibles that go along with Volvo ownership.

But for the last four years I have been dealing with a car that cracks fuel tanks and a company that has no interest in trying to solve the problem. The local dealer tells me his hands are tied and there is nothing they can do. They haven't seen this problem on other vehicles. Volvo North America says they haven't seen an issue either, and "I must just be unlucky." I have replaced the tank once with a Volvo factory new OEM part, and the second time it was replaced with a salvaged fuel tank. The problems I have had in the past were usually minor and more annoying than anything. But this seems to be a legit safety issue that Volvo refuses to offer assistance on.

I would like to know if anyone else has had a problem with the fuel tanks on 850 models that are not covered by the latest recall. Maybe I am just "unlucky" as Volvo puts it.

I am in the market for a new car for my wife. We are expecting our first child. At this point, the Volvo V70R we have been looking at is off the list. I assume the "Volvo for Life" slogan only refers to depreciable life.

John

File a complaint online the the website for the US Department of Transportation. I had a top of the tank leak which occurred only when I was filling the tank and only when the last gallon was going in. DoT was or is examining this problem for a possible recall. Even make a follow up phone call to the appropriate dept at DoT. I did and there is or was definitely someone there working on it. My conversatinos with them were in Jan of 2004.

If i am correct i think there is a recall on fuel tanks leaking on some 850's

check on volvospeed.com or call one of the dealers about the recall

The leak I am referring to and have heard about from several people is not covered on the recall. The leaks are appearing at the top of the tank. Some are a result of a "plug" missing from the fuel pump cap, others are just cracking.

I had my tank replaced under the recall. When it was off the car the dealer said my fuel pump wiring harness was leaking at the top of the tank. The "plug" you refer to is a glob of sealant that seals the area around the fuel pump wires going into the tank. Solution, replace the pump and wiring harness unit at a cost of $300 or squirt some RTV sealant or similar into the wiring to reform a seal - cost should be under $5 though the labor is surely a pain in the neck.

I wish Volvo would build a tougher vehicle today. They are well engineered but poorly built - unlike days past. A lot of the problems and failures I've had on my car were things I NEVER(!!!) thought would break, much less on a car this young!

Maybe try a fuel cell and mount it in the trunk, racing style. :)

Mine leaks as well when full and the dealer said it is not the leak that is covererd under the warranty. I need a new dealer.