Generations
240 — 240 Series
1974–1993
2.0L B20/B200 series, 2.3L B23 series
Top issues to watch for
The most serious Volvo 240 problems ranked by severity. We track 5 known issues — here are the ones you need to know about first.
Dangerous
Structural corrosion affecting load-bearing areas (240)
The 240 series suffers structural corrosion in load-bearing areas around suspension mounting points, particularly rear spring towers and subframe attachment points. MOT data shows this model fails at 11.2x the fleet average for subframe corrosion and 9x the average for general structural corrosion. This is a safety-critical issue as it compromises the structural integrity of the vehicle. The problem is progressive and affects cars from 100,000 miles upwards as the protective coatings fail with age.
What happens if ignoredIf structural corrosion progresses, suspension components can detach from the bodyshell, causing complete loss of vehicle control. Repair requires professional welding of new metal sections. Costs typically range from £800-£2000 depending on extent. The car is unsafe to drive if significant structural corrosion is present.
Independent garage
£800–£2,000
Specialist
£1,000–£2,500
Parts only
£200–£600
Dangerous
Flexible brake hose deterioration (240)
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. The rubber brake hoses deteriorate internally over time, causing reduced braking efficiency or complete brake failure. This affects all variants but is most severe on 2.0L models. Original specification hoses from the 1980s are now well beyond their safe service life.
What happens if ignoredFailed brake hoses can cause complete loss of braking ability on affected wheels or catastrophic brake failure. The vehicle should not be driven if brake hose bulging or fluid leakage is observed. Replacement of all flexible hoses is typically required on vehicles of this age.
Independent garage
£200–£400
Specialist
£250–£500
Parts only
£80–£150
Major
Suspension bush and joint wear (240)
The 240 series exhibits excessive suspension wear rates, failing MOT tests at 15.9x the fleet average for worn suspension pins, bushes and joints. The original rubber bushes deteriorate significantly after 30+ years, causing poor handling, tyre wear, and eventual MOT failure. This affects both front wishbone bushes and rear trailing arm bushes. The problem is universal on surviving 240s due to their age.
What happens if ignoredWorn suspension bushes cause poor handling, increased tyre wear, and eventual MOT failure. While not immediately dangerous, severely worn bushes can affect vehicle stability and braking performance. Complete suspension bush replacement is typically required on vehicles of this age.
Independent garage
£400–£800
Specialist
£500–£1,000
Parts only
£150–£350
Major
Suspension component corrosion (240)
MOT data shows the 240 series fails at 8x the fleet average for corroded suspension components. The steel suspension arms and mounting brackets suffer significant corrosion after decades of exposure to salt and moisture. This particularly affects the rear trailing arms and front wishbones where protective coatings have failed. Corrosion can progress to the point where components become structurally unsafe.
What happens if ignoredSeverely corroded suspension components can fail suddenly, causing loss of vehicle control. Professional assessment is required to determine whether components can be repaired or must be replaced. Replacement of corroded suspension arms typically required on high-mileage examples.
Independent garage
£300–£600
Specialist
£400–£800
Parts only
£120–£300
1 more known issues tracked
Including wear items, electrical niggles, and generation-specific problems.
MOT failure hotspots
Based on DVSA MOT test data. These are the items where the Volvo 240 fails at a significantly higher rate than the average car.
Headlight fault
Lights & Electrics · 150k+ miles
MOT failure rate: 246x the fleet average
Sample: 575 tests
Brake hoses perished or damaged
Brakes · 150k+ miles
MOT failure rate: 109x the fleet average
Sample: 1,379 tests
Suspension ball joints worn
Suspension · 100-120k miles
MOT failure rate: 60x the fleet average
Sample: 245 tests
Emissions failure
Exhaust & Emissions · 150k+ miles
MOT failure rate: 59x the fleet average
Sample: 3,437 tests
Wheel bearings worn
Suspension · 60-80k miles
MOT failure rate: 23x the fleet average
Sample: 104 tests
Seat mounting fault
Seatbelts & Airbags · 80-100k miles
MOT failure rate: 19x the fleet average
Sample: 153 tests
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Related
Volvo 240 reliability FAQs
What are the most common problems with the Volvo 240?
The Volvo 240 has 5 known issues across 3 severity levels. The most serious are: Structural corrosion affecting load-bearing areas (240), Flexible brake hose deterioration (240).
Is the Volvo 240 reliable?
The Volvo 240 has 2 dangerous and 2 major known issues. Most can be avoided with a thorough pre-purchase check and full service history.
How much does it cost to fix Volvo 240 problems?
Repair costs range widely. The most significant issue (Structural corrosion affecting load-bearing areas (240)) costs £800–£2,000 at an independent garage. Minor issues can be under £200. Always get a full inspection before buying.