I'm in the market for a first car for my son. I drive a 740 ['92] and it's held up VERY well in salty winter of Rochester NY. My '87 240 got eaten by the salt & I had to retire it after (only) 12 years. Outer body looked great, underside structure was weakened enough that I didn't feel "Volvo safe" driving it. Also got tired of welding, POR, & bondo......

How are the later 240's? Did they fix any of the rust-prone areas (floorboard, sill, or cowl) ? Or should I look for a rust free 740?

Most 240's rust from the inside-out. They are leak prone and the damage goes unseen under the carpets and padding until the owner notices holes in the floorpans.

I understand that from about '86-on Volvo began using a zinc-phosphate primer on the lower half of the body (lower doors, etc), and integrated the rear mudflap with the wheel arch to end the design flaw that gave rise to premature rust ouot behind the rear wheels.

It isn't fool-proof, as removal of the mudflaps may reveals a good bit of rust underway.

My 89 245 is rust free through 12 midwest winters. The undercoating is very thick and everywhere.