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OK, I guess I'll add my two cents here. I've owned two 960 (92 965 and my present V90). My son and family has the 92 now. Both have over 100K on them. If you like the 960 series, I would definetly look for a late model, 97 or 98. The models ended in 98. The engine block, from what I understand, lives on in every fron wheel drive Volvo on the road; they just lop off cylinders.
Both of my cars have been pretty trouble free, although the 92 had an AC compressor go out prematurely and a vacuum leak in the ACC (dash). These were pricey repairs. The 97 has been trouble free. Both have sythentics throughout. You can expect to get around 24-26 mpg on the highway, but it's on the highway where the 960 is a world apart from the 940s. Heavily ladden, or in mountains, mileage will drop, will drop but at 65mph you have plenty of punch left to leave those pesky 18 wheelers far behind. I get 13-16 in real city driving. For the highway driving youll be doing, I wouldn't be afraid of the 960 series. The later model years have a 21 gallon tank which helps this thirsty 6.
As for their reliability, we get mixed messages here, based in part I believe, on the sampling error and population size. After all, this is a forum for folks to seek help. That is not to say that the 960 is without its foibles. The vulnerability of the timing belt is reknown. It breaks, and your toast, but later models have a timing belt life of 70K. They can use oil, but usually not excessively. Others have reported gasket leaks and a gaggle of other complaints. Again, I don't know how to interpret these data.
I am very happy with the car. If you're hauling anything of consequence, I'd look for one that had nivomat self-leveling rear shocks, an option in later model years. Other 960 owners will weigh in, Im sure
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John Shatzer, '97 V90 @ 105K
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