1996 Volvo 960

TL* THE CONTACT OWNS A 1996 VOLVO 960. THE CONTACT STATED THAT FUEL FUMES EMITTED INSIDE OF THE VEHICLE. AFTER INSPECTING THE VEHICLE, THE CONTACT NOTICED THAT FUEL WAS LEAKING FROM THE FUEL TANK. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN STATED THAT THE LEAK WAS FROM THE FUEL RAIL AND THE FUEL RAIL NEEDED TO BE REPLACED. THE VEHICLE AS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 73,000. UPDATED 09/10/15*LJ UPDATED 11/27/2017*CN

RAW GASOLINE LEAKING FROM MANUFACTURE DEFECTIVE FUEL RAIL. MANUFACTURE MACHINED SEALED TAPET/FLANGED ALUMINUM SEAL ON FUEL RAIL LEAKING RAW GASOLINE UNDER HIGH PRESSURE IN ENGINE BAY. PROBLEM ONLY OCCURS DURING ENGINE OPERATION. RAW GASOLINE IS FLAMMABLE. FUEL RAIL DELIVER SYSTEM PART OF EMISSIONS SYSTEM. OCCUPANTS MAY OR NOT NOTICE GASOLINE SMELL (NOXIOUS FUMES) DURING OPERATION INSIDE CABIN. MANUFACTURER RECALL ADVISED. *TR

RAW GASOLINE LEAKING FROM MANUFACTURE DEFECTIVE FUEL RAIL. MANUFACTURE MACHINED SEALED TAPET/FLANGED ALUMINUM SEAL ON FUEL RAIL LEAKING RAW GASOLINE UNDER HIGH PRESSURE IN ENGINE BAY. PROBLEM ONLY OCCURS DURING ENGINE OPERATION. RAW GASOLINE IS FLAMMABLE. FUEL RAIL DELIVER SYSTEM PART OF EMISSIONS SYSTEM. OCCUPANTS MAY OR NOT NOTICE GASOLINE SMELL (NOXIOUS FUMES) DURING OPERATION INSIDE CABIN. MANUFACTURER RECALL ADVISED. *TR

LEAKING FUEL RAIL - OUR 1996 VOLVO 960, WHICH WAS BOUGHT NEW AND SERVICED REGULARLY BY VOLVO MECHANICS, DEVELOPED A BAD FUEL ODOR INSIDE THE CABIN, AND, WHEN I OPENED THE HOOD, IT WAS APPARENT THAT IT HAD A SERIOUS GASOLINE LEAK, WHICH WAS MODE WORSE WHEN THE ENGINE WAS HOT. I TRIED TO FIND THE LEAK, BUT COULDN'T FIND ANY FUEL LINES LEAKING. WE TOOK IT TO OUR LOCAL VOLVO MECHANIC, AND HE SAID IT WAS THE FUEL RAIL, AND SAID THAT IT WAS QUITE COMMON ON THAT MODEL. I ASKED HIM IF IT WAS DANGEROUS, AND HE LOOKED AT ME LIKE I WAS A COMPLETE DUMMY! WE HAD THE FUEL RAIL REPLACED, AT GREAT EXPENSE, OF COURSE, BUT I COULDN'T HAVE MY FAMILY AT RISK DAILY IN THE CAR. THERE APPEARS NOT TO BE A RECALL, BUT I AM HAVING ONE OF THE LOCAL PERSONAL INJURY ATTORNEYS LOOK INTO THE SITUATION. SURELY THERE IS A BULLETIN OUT ON THIS DANGEROUS SITUATION! *LN

I LIVE IN GA AND LAST FRIDAY I WAS COMING HOME FROM WORK IN THE RAIN, I HIT A BIG PUDDLE AND MY CAR STALLED OUT THEN CAME BACK ON AFTER I CLEARED THE PUDDLE, I CHECKED UNDERNEATH WHEN I GOT HOME AND THERE WAS NOTHING LOOSE THAT I COULD SEE. THIS WAS THE FIRST TIME THIS HAS EVER HAPPENED TO ME. MY CAR IS A 1996 VOLVO 960 WITH 177,000 MILES ON IT, IT RUNS GOOD BUT DOES HAVE OTHER ELECTRICAL ISSUES TOO. *TR

AT 110K I NOTICED COOLANT LEVEL DROPPING FASTER THAN USUAL, AND COOLANT ON GARAGE FLOOR. DEALER REMOVED SIDE ENGINE COVER AND SHOWED ME A LINE OF PINHOLE LEAKS IN THE ALUMINUM BLOCK. TECHNICIAN SAID THIS WAS A MANUFACTURING DEFECT HE HAD SEEN BEFORE, AND THAT THE ENGINE WOULD HAVE TO BE REPLACED. VOLVO OFFERED NO HELP, "OUT OF WARRANTY." I PURCHASED A USED 1998 960 ENGINE FOR $1900 AND DEALER INSTALLED FOR $1800, INCLUDING INCIDENTAL PARTS. SOON THEREAFTER, RADIATOR BLEW AND RUINED CYLINDER HEAD. THE 1 YEAR USED ENGINE WARRANTY COVERED CYLINDER HEAD AND I PAID ABOUT $800 FOR NEW RADIATOR. TOTAL OUTLAY $4500! I FOLDED MY CARDS AND GOT $3500 FOR VOLVO TOWARD A NEW TOYOTA COROLLA. NO MORE VOLVOS FOR ME! *NM

FOR THE PAST YEAR MY CAR HAS BEEN REEKING OF GASOLINE FUMES, NORMALLY IN THE MORNING WHEN COLD STARTING, BUT WOULD OCCUR PERIODICALLY THROUGHOUT THE DAY. THE SMELL WAS SO OVERWHELMING THAT I COULD NOT TURN THE HEATER ON IN THE CAR, AND WOULD HAVE TO PUT THE WINDOWS DOWN IN THE CAR WHILE DRIVING DOWN THE ROAD TO TRY TO RID THE CAR OF FUMES. I TOOK THE CAR TO THE VOLVO DEALER AND LEFT IT WITH THEM FOR DAYS. THEY ASSURED ME IT WAS A ACCUMULATION OF SOMETHING IN THE VENT SYSTEM, AND THEY CLEANED THAT OUT. THE PROBLEM STILL EXISTED. I FINALLY TOOK IT TO ANOTHER MECHANIC WHO FOUND THE PROBLEM. THE FUEL RAIL. THE END PIECE WOULD ALLOW FUEL TO VIRTUALLY SPILL OUT. PLEASE REFER TO THIS WEB SITE WHICH DESCRIBES THIS POTENTIALLY DANGEROUS SITUATION IN DETAIL: HTTP://WWW.VOLVOCLUB.ORG.UK/FAQ/960_90INFO.HTML#960B6300FUELRAILLEAKAGEPROBLEMS MY CAR WAS A POTENTIAL TIME BOMB. NOT ONLY DID VOLVO NOT FIND THE PROBLEM, BUT WHEN MY NEW MECHANIC FOUND THE PROBLEM IT TOOK MY MECHANIC THREE TRIPS TO VOLVO IN ORDER TO HAVE THEM ORDER THE CORRECT PARTS AS VOLVO NO LONGER MANUFACTURERS THAT PARTICULAR PART - HMMMM....I WONDER WHY. THIS COULD HAVE CAUSED A HORRIBLE SITUATION, ESPECIALLY WITH MY CHILDREN IN THE VEHICLE. WE EXPERIENCED SORE THROATS, AND FROZE TO DEATH ON COLD MORNINGS NOT BEING ABLE TO TURN THE HEATER ON DUE TO BEING FUMIGATED WITH GASOLINE FUMES. *NM *NM

THE FUEL RAIL BEGAN LEAKING FROM PLUG IN FRONT END OF RAIL. I WAS ABLE TO SMELL THE LEAK IN THE PASSENGER COMPARTMENT AND WAS ABLE TO AVOID A FIRE OR OTHER DAMAGE. LOCAL INDEPENDENT PARTS STORE INDICATED THAT THIS IS A COMMON PROBLEM WITH THE 960. BOUGHT A NEW, REDESIGNED FUEL RAIL FROM LOCAL VOLVO DEALER. IT WAS IN STOCK AND THEY INDICATED THAT THEY SELL A FAIR NUMBER OF THESE. THEY INDICATED THAT THERE IS NOT A RECALL ON THIS PART. THE NEW PART HAS A DIFFERENT DESIGN OF THE END PLUG WHICH LEAKED ON MY CAR. I NO LONGER HAVE THE OLD PART AVAILABLE. *JB

DT: THE CONSUMER STATED THAT 1996 VOLVO 960 VEHICLE WAS INVOLVED IN A CRASH. WHILE TRAVELING AT 40 MPH. UPON IMPACT, FRONTAL AND SIDE AIRBAGS DID NOT DEPLOY. CONSUMER'S VEHICLE HIT A CAR THAT DID NOT STOP AT A STOP SIGN. THERE WERE 2 INJURIES. THE CONSUMER CONTACTED VOLVO DEALERSHIP AND THE MANUFACTURER. THE CAR WAS TOTALED. A POLICE AND INSURANCE REPORT WERE TAKEN. ALSO, THERE ARE PICTURES OF THE COLLISION. *AK

AS OF JULY 29, 2005, MY 1996 VOLVO 960 STARTED LOSING SPEED AND THE ENGINE STALLS WITHOUT WARNING! THUS FAR, NO INJURIES HAVE BEEN SUSTAINED. THE CAR HAS BEEN TAKEN OFF THE ROAD. ON AUGUST 1, 2005, WBAL-TV REPORTED THE SAME PROBLEMS WITH 1999-2001 VOLVOS. MY CAR HAS ALWAYS BEEN MAINTAINED AND UP TO NOW HAS BEEN IN EXCELLENT WORKING CONDITION. PLEASE ADVISE. *NM

1996 VOLVO 960 SEDAN - FUEL RAIL LEAKAGE PROBLEM, FRONT OF FUEL RAIL DEVELOPED A LEAK AT A FACTORY PLUG (METAL). FUEL WAS POURING OUT BETWEEN METAL PLUG AND FUEL RAIL ONTO THE (HOT) ENGINE INTAKE MANIFOLD AND THERMOSTAT HOUSING. INQUIRED ABOUT PARTS TO REPLACE FUEL RAIL ASS'Y FOR A 1996 VOLVO 960, FUEL RAIL ASS'Y HAS BEEN SUPERCEDED BY A 1998 UP DESIGN. THIS IS A SERIOUS HAZARD WHICH COULD RESULT IN A FIRE AND POSSIBLE DEATH.

DT: CONSUMER STATES WHILE DRIVING HIS VEHICLE THE FAN RELAY SWITCH MELTED, CAUSING THE VEHICLE TO START SMOKING. AFTER STOPPING THE VEHICLE AND DISCONNECTION OF THE BATTERY THE SMOKE ENDED AFTER ABOUT 20 MINUTES. *TT

FUEL SMELL. *AK

THE POWER STEERING PIPE MADE NOISE. *NM THERE WAS A NOISE DURING PARKING MANEUVERS OR TRAVELING AT EXTREMELY LOW SPEEDS COMING FORM THE FRONT OF THE VEHICLE. THE A/C WOULD NOT COOL AND THE BRAKES PULSATED. (IN RE TO ODI# 10038186) *SC *JB

TWICE, IN MY 1996 VOLVO 960, I EXPERIENCED SUDDEN ACCELERATION. IN BOTH CIRCUMSTANCES I WAS ON A HIGHWAY AND IT WAS LATE AT NIGHT. I WAS UNABLE TO SLOW MY CAR DOWN IN ORDER TO TAKE AN EXIT RAMP. I EVENTUALLY PUT THE CAR IN NEUTRAL AND TURNED IT OFF. I WAS ABLE TO STOP THE CAR SAFELY, BUT THESE WERE THE MOST FRIGHTENING DRIVING EXPERIENCES OF MY LIFE. AFTER THE FIRST INCIDENT, MY DEALERSHIP REPLACED THE ACCELERATOR CABLE (WHICH APPEARED NORMAL) AND REPLACED MY BRAKES (WHICH I DESTROYED TRYING TO STOP THE CAR). AFTER THE SECOND INCIDENT (TWO WEEKS LATER), THE DEALERSHIP DISCONNECTED THE CRUISE CONTROL. THE PROBLEM HAS NOT REOCCURRED. I HAD NEVER USED THE CRUISE CONTROL ON THAT CAR.*AK

THE CONSUMER STATED THAT THERE WAS A STRONG CHEMICAL FUME SMELL INSIDE THE PASSENGER CABIN COMING FROM THE ENGINE COMPARTMENT. THE DEALER STATED SORRY, NOTHING COULD BE DONE. THE VEHICLE WAS RUNNING WITHOUT WARRANTY. *AK THE FUEL RAIL ALUMINUM HOUSING WAS LEAKING WHERE IT WAS A CRIMPED TOGETHER AT THE ENDS. GAS WAS LEAKING WHEN THE VEHICLE WAS COLD AT THE FIREWALL AND GAS FUMES WERE ESCAPING THROUGH THE VENTS INSIDE THE VEHICLE. *SC

DASH LIGHTS GO OFF AND ON WHEN THE HEADLIGHTS ARE ON. *AK

ODOMETER FRAUD FROM DEALERSHIP - VEHICLE WAS SOLD WITH AN ODOMETER READING OF 21,812. A FEW WEEKS AFTER THE PURCHASE THE CAR HAD PROBLEMS AND WAS TAKEN TO A REPAIR SHOP WHO NOTED THAT THE VEHICLE LOOKED LIKE IT HAD MANY MORE MILES ON IT. THROUGH CAR FAX WE FOUND THAT THE CAR HAD OVER 90,000 MILES. WE BOUGHT FROM A DEALERSHIP THAT IS PART OF A LARGE AUTO GROUP AND PRESUMED PROPER DUE DILIGENCE WAS DONE. WHILE WE DID GET A REFUND, WE FEEL IT IS IMPORTANT TO FILE A COMPLAINT SHOULD THERE BE OTHERS OUT THERE IN THE SAME SITUATION.*AK

WHEN MAKING A RIGHT TURN VEHICLE MAKES A LOUD NOISE. DEALER HAS ATTEMPTED TO REPAIR VEHICLE, BUT THE PROBLEM CONTINUES; DEALER CANNOT DETERMINE THE CAUSE OF THE PROBLEM. *AK THE POWER STEERING PIPE FAILED AND CAUSED A LOUD KNOCKING SOUND IN THE FRONT END. A SERVICE BULLETIN WAS ISSUED FOR THIS PROBLEM IN 1998. THE CONSUMER IS REQUESTING THAT THE REPAIRS BE MADE FREE OF CHARGE SINCE MANY UNNECESSARY REPAIRS WERE MADE TO THE VEHICLE TO ALLEVIATE THE NOISE PRIOR TO THE WARRANTY EXPIRING. THE A/C WAS NOT COOLING. THE REAR BRAKE ROTORS WORE BELOW SPECS. THE DEALER REPLACED THE ROTORS AND THE PADS. *TS *NLM

WHILE TURNING STEERING WHEEL TO THE LEFT OR RIGHT DRIVER WOULD HEAR LOUD NOISE COMING FROM STEERING COLUMN. *AK THE POWER STEERING PIPE FAILED AND CAUSED A LOUD KNOCKING SOUND IN THE FRONT END. A SERVICE BULLETIN WAS ISSUED FOR THIS PROBLEM IN 1998. THE CONSUMER IS REQUESTING THAT THE REPAIRS BE MADE FREE OF CHARGE SINCE MANY UNNECESSARY REPAIRS WERE MADE TO THE VEHICLE TO ALLEVIATE THE NOISE PRIOR TO THE WARRANTY EXPIRING. THE A/C WAS NOT COOLING. THE REAR BRAKE ROTORS WORE BELOW SPECS. THE DEALER REPLACED THE ROTORS AND THE PADS. *TS *NLM