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If you must have a Volvo, try the S60 or S40 models. After years of trial and errors (many), Volvo seems to have finally got it right in these vehicles.
The 850 was the first Volvo experiment in front wheel drive and many errors were made in this vehicle. A short list includes:
ac evaporator leaks---$1100.
rear main engine seal replacement $600-800
abs controller failure $500-600 to replace
it eats pads, discs and calipers at a rapid pace-- $300 per wheel
This does not include regular maintenance items.
If you want reliability and low maintenance costs, go for an Accord or Camry. If you are a crazy person like me, get an 850 (I own a 96 with 85k on it)and make very good friends with a Volvo tech who will work after hours on the things you cannot personally fix.
PS: I have owned two 240s in the past and found them to be just as maintenance intense as the 850 Volvo even though Volvo had years to reduce the bugs between 1968 and 1993. Volvo is only had 11 years into the 850-s70-s60 de-bugging process. Perhaps they are learning faster this time around due to more intense competition despite now being owned by Ford.
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