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I have a Volvo 940GLT / 1991 with B234F engine, AT + AC, and fight the same problem. The Volvo dealer's "specialists" replaced the starter and the solenoid, on my money of course, and wanted to replace many other parts including the inhibitor. This happened almost two years ago and since then I always have the same problem, not so often during winter (when it is colder outside).
Even if I am not a mechanic or engineer I am sure the cause is the overheating of the engine, because of the malfunctioning of the fan clutch. I am sure about this, because I cannot find any other explanation for the fact that (in order to avoid waiting 30-60 mins for the engine to cool down) I use an original and faster method: I always have in the trunk 1-2 PET bottles with water. When the starter is "dead" I sprinkle it with water and in 20 - 30 sec it will start operating.
REMARK: USE PLASTIC BOTTLES ONLY, AS THEY DO NOT BREAK AND CAN BE USED LIKE A SPRINKLER.
As cooling the starter makes it work again, this is only a matter of overheating. This is maybe due to the fact that, when normally cooled, the engine does not reach the critical temperature for the starter and solenoid. Both these items have / must have a lower operating temperature than the one reached under certain circumstances.
I shall very much appreciate any comments on my answer, mainly because I found the Brickboard's website while searching the net for the bloody fan clutch. Even if I am from Bucharest, Romania, I prefer to buy it from the states (or from anywhere else on earth) at a 4 - 6 times lower price than at the local Volvo dealer's one.
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