Recall 21V766 covers 259,383 2001-2009 Volvo S60 and S80 vehicles for driver air bag inflators that can explode. Repair will be free once available.
Volvo is recalling 259,383 2001-2009 S60 and S80 vehicles under recall 21V766 because the driver's air bag inflator can explode during deployment after long-term heat and humidity exposure. Sharp metal fragments can strike the driver or passengers, causing serious injury or death, and the Volvo dealer repair will be free once available.
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What's wrong?
The driver's air bag assembly in the 2001-2009 Volvo S60 and S80 includes an inflator, the metal canister that fills the air bag when a crash sensor calls for deployment. Inside the FG2 twin inflator, 5AT 148N propellant burns quickly to create gas and inflate the driver's air bag in front of the steering wheel.
On affected vehicles, long exposure to high humidity, high heat, and repeated temperature changes breaks down the propellant tablets inside the inflator. Moisture moves in and out of the tablets as temperatures rise and fall. Over time, that process creates dust, which increases the burn surface inside the inflator. The propellant then burns faster than designed, raising pressure inside the inflator and creating a risk that the metal inflator ruptures during air bag deployment.
The highest-risk vehicles spent their lives in hot, humid conditions, but the driver does not get a clear dashboard warning or driving symptom. There is no warning sign before failure.
Who's affected?
Spans the S60 and S80 across the 2001-2009 model years, all tied to the same driver side front air bag inflator module.
| 2001 Volvo S60 | front air bag |
|---|---|
| 2002 Volvo S60 | front air bag |
| 2003 Volvo S60 | front air bag |
| 2004 Volvo S60 | front air bag |
| 2001 Volvo S80 | front air bag |
| 2002 Volvo S80 | front air bag |
| 2003 Volvo S80 | front air bag |
| 2004 Volvo S80 | front air bag |
| 2005 Volvo S60 | front air bag |
| 2005 Volvo S80 | front air bag |
| 2006 Volvo S60 | front air bag |
| 2006 Volvo S80 | front air bag |
| 2007 Volvo S60 | front air bag |
| 2008 Volvo S60 | front air bag |
| 2009 Volvo S60 | front air bag |
| Units affected | 259,383 |
| Field incidents | NHTSA has logged 1 field incident to date. |
The year and model narrow the scope, but the VIN decides. Check your VIN to confirm whether your specific sedan is included.
What's the safety risk?
The driver air bag inflator can explode and send sharp metal fragments into the driver or passengers, causing serious injury or death. Risk is highest after frequent hot, humid exposure over the vehicle's life. Schedule the repair soon. Repair will be free at any franchised Volvo dealer once available.
What should I do?
- Check your VIN to confirm your 2001-2009 Volvo S60 or S80 is included in this recall.
- Use Volvo's owner letter, mailed November 29, 2021, to confirm the recall instructions for your VIN.
- Contact Volvo customer service at 1-800-458-1552 and reference recall number 21V766 and Volvo recall R10125.
- Ask a franchised Volvo dealer about the free driver's air-bag replacement that fixes the inflator explosion risk.
- Bring the recall notice and any dealer paperwork when Volvo confirms the repair path for your vehicle.
- Limit driving until the driver's air-bag inflator is replaced, since an inflator explosion can send sharp metal fragments into the cabin.
What happens at the repair
Volvo has identified the dealer remedy: a Volvo technician will replace the driver's air bag. Because the final process is still being developed, do not treat the final appointment as open until Volvo or the dealer confirms parts and scheduling. Once available, the replacement parts and labor will be free under the recall. Volvo has a general reimbursement plan on file, so keep documentation for any prior driver's air bag repair and ask Volvo Customer Care or the service desk how to submit it.
| Reimbursement | Reimbursement available |
|---|
Timeline
| September 30, 2021 | NHTSA published the recall |
|---|---|
| September 30, 2021 | Dealer notification began |
| September 30, 2021 | Dealer notification ended |
| November 29, 2021 | Owner notification mailed |
| November 29, 2021 | VIN-searchable in NHTSA's database — Check your VIN to see whether this recall applies to your specific vehicle. |
| November 29, 2021 | Interim owner notification (was planned for this date) |
Frequently asked questions
What is recall 21V766?
Recall 21V766 covers 259,383 2001-2009 Volvo S60 and S80 vehicles with a driver's air bag inflator that can explode during deployment after propellant degradation. Sharp metal fragments can strike the driver or passengers. Volvo dealers will replace the driver's air bag for free.
What should I do if my 2001-2009 Volvo S60 or S80 is on this recall?
Check your VIN to confirm your specific vehicle is included in recall 21V766. If it is, call a franchised Volvo dealer and ask for the free driver's air bag replacement. Reference recall number 21V766 and Volvo recall number R10125 when you call.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost. Volvo dealers will replace the driver's air bag free of charge, including parts and labor, for vehicles included in recall 21V766.
What is the safety risk in recall 21V766?
The safety risk is an inflator explosion during air bag deployment. If the inflator ruptures, sharp metal fragments can strike the driver or other occupants, resulting in serious injury or death. The repair path is the free driver's air bag replacement at a franchised Volvo dealer.
What if I bought my Volvo S60 or S80 used?
The free recall repair still applies. Recall coverage follows the vehicle, not the first owner. If you never received Volvo's owner letter, check your VIN, then call a franchised Volvo dealer or Volvo customer service at 1-800-458-1552 with recall number 21V766.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/21V766000 |
|---|---|
| Volvo customer service | 1-800-458-1552 |
| NHTSA recall # | 21V766 |
| NHTSA recall # (full) | 21V766000 |
Source documents
-
Download Recall Document (PDF) (PDF) - Download Misc. Document (PDF)
- Download Quarterly Report (PDF)
- Download Recall Document (PDF) (PDF)
- Download Recall Investigation Document (PDF) (PDF)
- Download Owner Notification Letter (PDF)
- Download Owner Notice (PDF)
- Download Recall Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 20, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →