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I had a similar problem with my 2004 9-5 Aero wagon. Right before the warranty was ending at 50,000 miles my fuel guage started sticking when refueling close to an empty tank. The dealer "repositioned" the baffle but I think it broke loose again as I could hear it clunking around when I stopped. The mechanic said they could install a new baffle but I risked it breaking free again eventually. So I just had them remove the baffle for good. A little more fuel slosh when I stop now but no fear of the baffle coming loose and causing expensive damage to the fuel gauge sender unit.
posted by 69.148.17...
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2015,5 Volvo V60CC T5
2014 Volvo S60 T5
2003 9-5 Aero Sedan (sold)
2004 9-5 Aero Wagon (sold)
1996 NG900 (sold)
1989 900 (donated)
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