Thank you all for your suggestions. Quite suprisingly, my entire wiring harness is in excellent condition. (1983 244GLT/130K miles). After experiencing the "crumbling" wiring syndrome in my 84 wagon, I almost have to think that the harness in my 83 was replaced at some point. I did however check the voltage at the battery while the car was running and discovered that indeed it was only putting out about 11.4 volts (regardless of RPM), so I am assuming that this is what is causing my caution lights to illuminate full time. Now to my second question. Should I replace the entire alternator or just get the new adjustable voltage regulator from IPD and replace that and the brushes? I'm not very knowledgeable about what causes alternators to suddenly put out a lower than normal voltage. It would be nice to save a little money and get the adjustable regulator to boot, but am I being penny wise and pound foolish?

Thanks - Bill

Forgot this option - junkyard unit with exchange policy. I've pulled a few from (relatively) low-mileage RWD Volvos and all were good.
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Bob (son's 81-244GL B21F, dtr's 83-244DL B23F, 'my' 94-944 B230FD; plus grocery-getter Dodge minivan, hobbycar 77 MGB, and numerous old motorcycles)

Low hassle alternator test: remove belts and spin it by hand...if it turns freely without noises, it is probably in decent shape mechanically and does not need a rebuild, so the brush/regulator purchase is lookin' good.

More hassle: remove alternator and take it to one of the (many) places that offer a free test. This may confirm bad brushes/regulator or perhaps a diode problem. They will try to sell you one of their units: resist, unless you feel inclined to throw down the cash for a reman Bosch. While it's out of the car, pull the regulator and brush assembly from it and check brush length. I can't remember what the minimum should be, but you can search archives here for that. If brushes are below spec you have likely found the problem and also the cheap fix.
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Bob (son's 81-244GL B21F, dtr's 83-244DL B23F, 'my' 94-944 B230FD; plus grocery-getter Dodge minivan, hobbycar 77 MGB, and numerous old motorcycles)

Hello,

You could try a new reg provided that your current one isn't rusted to the alternator and they are easily obtained at your local pick 'n' pull, but to avoid problems I would go for a rebuilt BOSCH alternator. No aftermarket crap.



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Happy Bricking!!! - Richard - '87 245 DL , '82 242 GLT - Volvo's are alive and well in Brampton!!!