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Consumer Reports had the 960 on it's "used cars to avoid" list and currently has the SV90 on it. The 960-SV90 problems (in a nutshell) are: 1.) the motor uses a timing belt and not a chain and it's an interference motor, meaning the pistons will crash into the valves if it breaks. $$$$. 2.) when you rebuild the head the block is aluminum and wears more quickly than an iron block . For a tale of what may happen, search the archives for "Christine" for one sad and expensive story. 3.) on early 960s there was the "engine block porosity' problem, apparently when Volvo started doing these relatively long castings there was a problem filling the casting with the alloy, this sometimes lead to the block "weeping" or internally leaking coolant or oil. It "seems" this was mainly "early" 960s, but Tom I**** described an internal Volvo bulletin suggesting that this may not always be the case. This particular casting problem is unreported on 850/SVC70s and for that matter on S80s. At least on "brickboard". 4.) again the block is alloy. When it overheats you throw out the big piece of aluminum and replace it with a factory rebuild. Used 960 motors are hard to come by, see items #1,2,3,4. Again, $$$$.
Besides the motor there is the problem of countless electronic gizmos to break. Swedish electric gizmos have never been known for their reliability and don't improve with age. Then there are the Nivomat shocks in the rear ($$$). It's also been posted here that the 940s actually cost more than the 960s to build mainly because of the methods used to assemble the interior of the 960. If true, something must have been cut out of the process.
The 940 Turbo is, according to most contemporary magazine tests actually faster than then 960 and handles better with it's unsophisticated live rear axle.
If I had a 960, I'd probably maintain it "by the book" with synthetic oil and drive it until the wheels fell off, but I certainly wouldn't recommend buying one used. I have no doubts that some people drive their 960s 200,000 miles without problems. I also have no doubts that other people have absolute Steven-King type nightmares with 960s, since some have been posted at Brickboard.
If you want a used I-6 look for a BMW, the sixes have chain-driven camshafts, so they don't need replacement. (Also avoid a V8 or V12 or any 7-series Bimmer). Or look for one of the older Mercedes 300Es before they "went cheap" and stuck in the V6. Or buy a Lexus V6 (or, better still, a V6 Camry) and have a life.
-Phil de Cassandra
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