Just an update: I had a leaking gas tank (near the driver's side heat shield attachment) on my 96 850, took it to a Volvo dealer and they fixed it (twice, even) for free.
The first time they added rubber bushings to the heat shield bolts, but it still leaked so they replaced the tank with a new one. ($550 online, by the way). I had to wait two days for the tank to come in and they even gave me a loaner car, all for free.
I was very grateful, as it probably would have cost $700-800 with labor.

 

My wife is going in for the recall tomorrow on the '94. Over the last couple of weeks she has been having a gas leak if she fills up over 1/4 tank but I have not yet suited up in the grubby clothes to crawl under the car to investigate the leak.

Hopefully, if she does have a bad tank which I suspect, our experience will be as good as yours.

My son is off at college with no nearby dealer but he thinks he also has a leak on his '96.

Given the failure rate, I need to get my Platinum scheduled. So far it doesn't leak.

...Lee

 

Yes, I hope you have good luck with the dealers, too. (Somewhere on this forum I read of folks being turned down by a dealer, but can't find that thread.) I called Volvo headquarters before visiting the dealer and was told it was covered.
My car had only about 1/4 tank of gas when I first took it in, and after the installation of the bushings I drove next door to a gas station and filled up, only to see the leak, whereupon I drove back to the dealer. It might save you a step if you fill the car before you take it in. That way if they try the bushings first and it doesn't work, they can immediately see the leak while they have it up on the rack.
Also of note: after the new tank was installed, there was a brand new leak under the fuel line attachment point. Fortunately I saw this before I checked out, and they put it back on the rack and tightened/adjusted some connections which fixed it. Mechanic said "It's hard to put old things on new ones".

 

The leak was confirmed today and the new gas tank goes in early next week when the parts come in.

Perhaps fortunately, they didn't offer her a loaner car. The last thing I need is for my wife to get real excited about a new XC60 after driving one for a few days.

Do you know if they changed the fuel pump and fuel gauge sender seals as a part of the tank change? I would be willing to buy some new parts to get things done right if they don't actually change them out as a matter of course.

...Lee

 

Hello,

My 95's fuel tank has been leaking for a while when I fill it past 6 gallons. I dropped the tank and replaced all the hoses and reinstalled it, to no avail. Today I caught it in the act. It looks like it is leaking from one of those heat shield fixings. The funny thing is I took it in for the recall a few years ago and they supposedly fixed it then. Anyway, here is the photo:

 

It could be the dealer added rubber bushings to the attachment points, instead of replacing the tank. That's what happened to me- they tried the cheapest thing first (which is my SOP, too.) I had to go back a second time and get the tank replaced.

 

Thanks. My wife is on her way there now to have them look at it.

 

Hmm. Tucson Volvo agrees it leaks at the heat shield mounting, but they won't replace it for free since it already had the rubber bushings installed as part of the recall a few years ago. They offered, as a "goodwill gesture", to pay for the parts if we would pay $250 for the labor. Does this sound right to you all?

 

Well, that sounds better than paying for all of it yourself, but not as good as paying nothing. The tank goes for $550 online, so you'd be saving that much at least. But I'd call Volvo headquarters first Volvo Cars | Contact Us and verify if the recall (campaign, they call it) is still good, and if so, inform them that your local dealer is not honoring it and ask them what they recommend. The recall was still in effect in Sept 2011 when I got mine fixed. It seems to me that, if the recall is still valid, the dealer should fix it at any cost, as a safety issue. The dealer may just be trying to save themselves some bucks by passing the cost of labor on to you.