Rattling began at 20,000 miles. The dealer was unable to resolve the problem.
The panels feel apart, but the dealer covered them under warranty.
Leather seats wore down at 50,000 miles. Mind you I only weigh 165 pounds.
ABS Brake Sensor broke at 60,000 miles. I asked the dealership about this problem because the guy standing next to me had the same problem. The service person said that this problem is common and to expect it to happen in another 60,000 miles. Cost $700 to repair (must be more expensive to fix in New Jersey).
At 60,000 miles the struts and shocks needed replacing, but I've forgone that expense and have accepted the seriously rough ride.
The window control (which also controls the sun roof) unit has just broke at 81,000 miles. I'm not looking forward to this repair bill.
Lights on the shifter and radio no longer function.
The headlight switch needs to be jiggled in order to work.
The performance and paint job are great with this car, but it pretty much ends there. The traction is bad in the snow unless you get snow tires. The traction is bad on a dry summer day unless you have Z-rated performance tires. The repairs are prohibitively costly.
I love my 1998 Volvo T5 though it "broke my heart" (my savings account too) when the replacement timing belt came off at 90,000 miles and I had to have the top half of the engine rebuilt. It is somewhat costly to repair and maintain (smart folks use expensive synthetic oil and often with a turbo). It is so comfortable and passes/merges/weaves very well. Brakes are excellent though the tight suspension means you feel the road bumps. Takes curves very well for a big car and I like the "road worthy/ heavy car" feeling. Nevertheless when I hear horror stories from other T5 owners I have no trouble believing them.
T-5 is a nice ride. All around comfortable road car. Sweden built. We have been very lucky. Maintain it and it keeps on running. Great for highway and all around sport ride.
Fix it and it will be a nice car to own if you are lucky like me. Usual maintenance plus some extras. 196K and smiling through.