Volvo 240 MOT Failures

An analysis of 21,953 real DVSA MOT tests on the Volvo 240 — what fails, how often, and how that compares to every other car on UK roads. Generations covered: 240 (1974–1993).

Where the Volvo 240 fails its MOT

The single biggest MOT failure point on the Volvo 240 is brake hoses perished or damaged — this model is 109 times more likely to fail on this item than the average car on UK roads. That makes it an extreme outlier for anyone buying or owning this model. Across 21,953 MOT tests, 20.37% of all Volvo 240 tests recorded this as a failure.

Brake failures on the MOT range from worn pads and discs (routine maintenance) to corroded brake lines and seized calipers (more serious). Check for any pulling under braking and listen for grinding.

Other notable weak points include headlight fault (246x the fleet average), seat mounting fault (19x the fleet average), suspension ball joints worn (60x the fleet average), and emissions failure (59x the fleet average). These ratios compare the Volvo 240's failure rate on each item against the national average for all cars tested — a ratio of 10x means this model fails ten times more often than a typical car.

The failures span 5 categories: Brakes, Lights & Electrics, Seatbelts & Airbags, Suspension, Exhaust & Emissions. If you're inspecting a Volvo 240 before purchase, these are the areas to focus on — and if any have been flagged as advisories on a previous MOT, they're likely to become failures in the near future.

How failures change with mileage

The Volvo 240's weak points shift as the car covers more miles. Understanding these patterns helps you know what to expect — and what to budget for — at each stage of ownership.

60,000 to 100,000 miles

This is where routine wear items start to show up. Brake components, tyres, and exhaust parts have done serious work by this point. Cars that have been well serviced will show fewer of these failures — this mileage band is where good maintenance really separates the well-kept from the neglected.

For the Volvo 240 specifically, the DVSA data shows the most common failures at this mileage are brake hoses perished or damaged (31x the average) and wheel bearings worn (23x). seat mounting fault (19x) and suspension component damaged or corroded (11x) also appear frequently.

Over 100,000 miles

High-mileage cars accumulate failures across multiple systems. The key question isn't whether things will need doing — they will — but whether the car has been maintained well enough to keep on top of them. Look for a consistent service history and recent MOT passes with minimal advisories.

For the Volvo 240 specifically, the DVSA data shows the most common failures at this mileage are headlight fault (171x the average) and suspension ball joints worn (60x). seat mounting fault (13x) and abs fault (11x) also appear frequently.

The shift from brake hoses perished or damaged at lower mileages to headlight fault at higher mileages is typical — early failures tend to be design or factory-related, while high-mileage failures reflect accumulated mechanical wear. A car that's been well maintained will usually dodge the worst of both.

Known issues beyond the MOT

An MOT only tests roadworthiness at a single point in time — it won't catch developing faults, intermittent problems, or issues that haven't yet reached the failure threshold. These are the issues that Volvo 240 specialists and owners flag most frequently, drawn from manufacturer technical bulletins, workshop data, and verified owner reports.

Structural corrosion affecting load-bearing areas (240) Dangerous

The 240 series suffers structural corrosion in load-bearing areas around suspension mounting points, particularly rear spring towers and subframe attachment points. Affects 240; typical independent garage repair cost is £800–£2,000.

Flexible brake hose deterioration (240) Dangerous

The 240 series shows exceptionally high rates of brake hose failure, with MOT data indicating failure rates of 16.9x the fleet average for damaged hoses and 108.9x for hoses bulging under pressure. Affects 240; typical independent garage repair cost is £200–£400.

Suspension bush and joint wear (240) Major

The 240 series exhibits excessive suspension wear rates, failing MOT tests at 15.9x the fleet average for worn suspension pins, bushes and joints. Affects 240; typical independent garage repair cost is £400–£800.

Suspension component corrosion (240) Major

MOT data shows the 240 series fails at 8x the fleet average for corroded suspension components. Affects 240; typical independent garage repair cost is £300–£600.

For the complete picture — including repair costs across independent, specialist, and dealer garages — see the full Volvo 240 common problems breakdown.

What to check before buying a Volvo 240

Based on the MOT failure data and known issues above, here's what to prioritise when inspecting a Volvo 240:

Brakes — check for brake hoses perished or damaged. Lights & Electrics — check for headlight fault. Seatbelts & Airbags — check for seat mounting fault. Suspension — check for suspension ball joints worn, wheel bearings worn, suspension component damaged or corroded, abs fault.

Beyond the MOT items, ask specifically about structural corrosion affecting load-bearing areas and flexible brake hose deterioration. These won't show up on a standard MOT but can be expensive to fix — repairs start from £800. A specialist pre-purchase inspection is worth the investment on this model.

Always check the car's full MOT history for patterns — recurring advisories often become failures within 12 months. And verify the service history to confirm maintenance has been kept up to schedule. Enter any reg into our free car check to see the complete picture.

MOT failure data sourced from DVSA bulk test records via data.gov.uk. Ratios compare this model's failure rate against the national fleet average. Known issues sourced from manufacturer bulletins, specialist workshops, and verified owner reports.