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This post is in response to a series of messages on Tuesday, April 25 by daidnik. Daidnik: Thanks for offering to submit the results of your soldering experiment. We will be interested to hear about your results on your 960.
In the past, other brickboarders have posted requests to call the National Highway Transportation Safety Administration about this problem. True, we are dealing with cars which are 10+ years old, but I believe this faulty design deserves to be corrected by the manufacturer. If you buy a replacement you will see that Volvo significantly changed the design of their fuel rail in an attempt to avoid leaking problems that resulted from their original poor design of the end cap on the 960.
A few months ago my '95 960 began seeping fuel from the front of the rail and I saw more than a few entries on brickboard.com about this 'not-uncommon' problem. Several of the postings urged other owners who experienced this problem to file with the NHTSA.
I recently submitted a complaint to the NHTSA . Or, Phone: 1-888-327-4236. Let me know if anyone is interested, and I can post a copy of my statement to the NHTSA.
Incidently, Volvo sent a recall notice shortly after my wife bought her 2004 V40. Different fuel rail construction, but similar symptom. If anyone is interested, I can take the time to post details of Volvo's recall letter, which admits their design flaw on the V40. It is interesting that Volvo did not fess up to the same problem with the 960 fuel rail design.
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