I have a 240 DL wagon (250k) that seems to be eating starters. 2 years ago the original one quit so I replaced it with a non-Bosch rebuilt and it lasted until about 2 months ago. It started to develop an ugly noise and then quit altogether and would just spin (whirring noise). I had it towed to a place and the Volvo mech. showed me how the starter had turned to mush inside. He replaced it with a used, not rebuilt, Bosch and it worked and sounded great - solid, quiet etc. It lasted for a month and then started to make the same grinding type noises. I called him and he said:
a) I could be 'over-cranking' it! I'm not. I do need to replace the AMM but it still starts and is driveable.
b) It could be the flywheel, as in missing teeth etc.
We had the starter out today and he had me run my fingers across the flywheel teeth and told me they were chamfered, but he couldn't find any missing. I couldn't tell because the flywheel was too hot to touch for long.
Has anyone heard of this chamfering before on a 240 or is he trying to avoid saying that the starter he put in could have had a short life? He wanted to sell me another one from a 740 but I don't want to throw more money at it until I figure out whats up. He put the old one back in (against his will) and I know I am on borrowed time. Thanks for all help.