Top 10 Most Common Problems on the Volvo 240
By ipd Staff
Even though the 240 has been out of production for almost 17 years, it is still a popular car among Volvo enthusiasts and a favorite among our staff. Over the past 35 years since it was introduced, we have come to know quite a bit about the iconic model. Here’s a list of some of the most common issues to look out for on the 240 if you are thinking of picking one up for a project or daily driver.
Main Fuses 1975-1993 240 Models
The main fuse box is located in the driver side kick panel and sufferes from a few design flaws. First, the fuse box is susceptible to corrosion from water that can enter the interior and drip directly onto the fuses. Second, the small contact area of the European ceramic style fuses also leads to corrosion due to electrolosis. Prevent numerous problems associated with the fuse box, by pulling all fuses and cleaning them annually.If you encounter a intermittent or no start issue on your 240, you can often get going again by simply spinning the fuses in their holders, which reestablishes electrical contact. Ceramic Fuse Kit for 240 and 260 Series
30-Piece Fuse Kit Contains: (15) 8-amp fuses, (10) 16-amp fuses, (5) 25-amp fuses |
| 30 Piece fuse kit | | MR-3E1000 | Reg. $5.95 | | Each |
Heater Fan 1975-1993 240 Models
The 240 is famous for it’s powerful heater, which according to urban legend can brown a slice of toast in about 30 seconds, however the heater blower motor is buried in the deepest confines of the dash. It’s like they built the car around the heater motor! Fortunately the motors are of decent quality and if you’re lucky you’ll only have to replace it one time while you own the car. Replacing the motor can take 3-4 hours for an experienced mechanic and we’ve heard of reports of it taking all weekend from some beginner do-it yourselfers! | Heater/AC Blower Motors | | 200 series | 1975-93 | kit w/resistor & switch | | MR-1370241K | Reg. $82.70 | | Each | | 700 series | 1983-87 | blower motor (1) | | MR-3506325 | Reg. $56.31 | | Each | | 700, 900 series | 1989-95 | blower motor (2) | Four Seasons | MR-3537854 | Reg. $83.16 | | Each |
(1) - 5 mounting screw style.
(2) - 3 mounting screw style. Not for use with automatic climate control.700 series blower motors also available
900 series blower motors also available
OD Relay, wiring, switch and solenoid 1975-1988 240 Models
Why in the world Volvo chose to use an electronic overdrive instead of a real 5 speed manual transmission is beyond us, but they did and we have all suffered that decision! It proved to be a troublesome system over the years and here’s a few of the most common issues. Most common problem with the overdrive is due to the shift knob accidentally being pulled off of the shift lever (while trying to engage reverse), which results in the OD button wires being disconnected from the switch. Next is failure of the OD wires just below the shifter, where they simply fail from being flexed back and forth thousands of times. The switch in the gear shift knob can also go bad and don’t forget to check the wiring where it connects to the solenoid on the driver side of the transmission as the wires often get disconnected by accident. Last on the list are the solenoid and the overdrive themselves. The overdrive works off of hydraulic pressure and as they age, they begin to lose pressure and engagement will become unreliable. Often replacing the lightweight Type F auto trans fluid used in them with a 30-50 weight will provide a few more years of service. | Overdrive Relays and Buttons for Automatic Transmissions | | A. 200, 700 series | 1981-84 | OD relay (orange) | | MR-1307793 | Reg. $39.13 | | Each | | B. 200 series | 1982-93 | OD push button | Volvo OEM | MR-1259708 | Reg. $23.91 | | Each | | B. 740, 760 series | 1983-90 | OD push button | Volvo OEM | MR-1259708 | Reg. $23.91 | | Each | | C. 200, 700, 900 series | 1985-95* | OD relay (white) | | MR-3523804 | Reg. $43.27 | | Each | | 200, 700, 900 series | 1982-95 | auto OD solenoid | Aftermarket | MR-1239928 | Reg. $79.06 | | Each | | 240, 740, 940 series | 1983-95 | kick-down cable for AW70/71 | | MR-1239932 | Reg. $59.90 | | Each |
*Fits most 700 and 900 models. Call for details.
Motor & transmission Mounts 1975-1993 240 Models
The 240 goes through engine and transmissions mounts on a regular basis! To prevent serious damage you’ll need to inspect them annually. Be prepared to replace them every 2-3 years depending on how hard you drive the car. The reason for the unusually short lifespan of these parts is due to the safety related design. The mounts are designed to allow the engine to move back and under the car, keeping it out of the passenger compartment in the event of a serious head on collision. | Transmission Mounts | | 240 series | 1975-93 | A | M41, M46 | APA | MR-1221967 | Reg. $10.68 | | Each | | 240 series | 1975-81 | A | BW55 | APA | MR-1221967 | Reg. $10.68 | | Each | | 240 series | 1982-93 | B | auto trans. | APA | MR-1359138 | Reg. $5.98 | | Each | | 240 series | 1975-81 | B | M45 4 spd. | APA | MR-1359138 | Reg. $5.98 | | Each | | 240 series | 1986-89 | B | M47 5 spd. | APA | MR-1359138 | Reg. $5.98 | | Each |
| Motor Mounts | | 240 series | 1975 | C | All | Both sides | APA | MR-274110 | Reg. $8.95 | | Each | | 240 series | 1976-93 | C | All | Left side only | APA | MR-274110 | Reg. $8.95 | | Each | | 240 series | 1976-93 | D | All | Right side only | APA | MR-274111 | Reg. $8.95 | | Each |
For trans mounts for 700/900 series cars please check our website
For motor mounts for 700/900 series cars please check our website
Flame Trap System 1976-1993 240 Models
Another Volvo oddity is the use of a flame trap system where every other car manufacturer in the world uses a PCV system incorporating a PCV valve. Volvo has had problems with this system since it was introduced in 1976. Volvo's still run into the same issues on their newer models. Possibly in theory Volvos system is better, but in reality it gets overlooked and inevitably becomes clogged up and causes oil leaks and idle problems.
240 Flame Trap System Components
700 series Flame Trap System Components
900 series Flame Trap System Components This article continues on page 2 |
