Our '91 740 developed a miserable leak in the power steering.

Turned out to be one of the small steel pipes that runs from the valve to the rack body -- pinhole rusted through.

Removed it, washed it out, wire brushed it, ground around the pinhole with my Dremel, and soldered it using plumbing solder and a propane torch.

And painted it.

Works great, at least for my 3-mile test drive.

Fortunately, I had replacement o-rings of the right size (tiny suckers) in my el-cheapo Harbor Frieght "10,000 o-rings fer $9.99" kit.

This is the second time in 8 months that I've had a leak in the power steering from a rust hole. It's that %$#@ing Massachusetts road salt.

Also replaced the exhaust system at 236k miles. The old one was original. (Maybe I shouldn't complain too much about rust...)
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Don Foster (near Cape Cod, MA)

I think that it's just shameful that you would have to replace an exhaust system after a mere 236,000 miles. If I were you, I'd have to climb up on a soap box and start griping about it :-)
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-------Robert, '93 940t, '90 240 wagon, '84 240 diesel (she's sick) , '80 245 diesel

You're right, you're right.

I figure I coulda got another 100,000 miles out of it if wifey hadn't backed into that snow bank and snapped off the tailpipe...
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Don Foster (near Cape Cod, MA)

I would have if she had brought the broken part home......

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Don Foster (near Cape Cod, MA)

Well let's see, if she broke the thing, doesn't that mean that she has to let you buy another Volvo???
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-------Robert, '93 940t, '90 240 wagon, '84 240 diesel (she's sick) , '80 245 diesel

We discussed that......

I have to give up one of the eight in the yard before I can bring in another.

And I absolutely will NOT put her in a new car. Can you imagine how many times she has hit other Volvos in the driveway when backing hers out? If she were driving through the desert and there was a lone cactus 500' off the road, that cactus would be in mortal danger....

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Don Foster (near Cape Cod, MA)