Hi Auntie Volvo Queen,

You have options beyond Ziebart rustproofing.

I do not know their process, yet I'll guess they seal all under body (undercarriage) seams including inside the unibody frame tube rail compartments that run from front to back of the unibody, more of less, the rocker panel interiors, and may access the the door and other exterior body compartments by removing the door panels, the tail gate panel, remove the seats and carpet to reveal under body compartments.

See https://www.brickboard.com/FAQ/700-900/BodyRust.htm

I'll guess a place like Ziebart focuses on exterior access-only compartments.

To help with keeping the doors dry on the inside by replacing the exterior window scrapers (if not replaced already). The factory-installed vulcanized rubber window scraper shrink in length and harden, so water intrudes into the door interior. In the freezing month, water gets into the metal folds at the bottom of the door, freeze and expands and breaks the painted and factory sealant and moisture displacing preparation one could call undercoating. More like waxy lithium grease.

You can purchase new window scraper that you have to install yourself, or have your Volvo 240-familiar or mechanic to install these.

Sources are:
- nhttp://www.davebarton.com/240WindowMoldings.html (I think these are rubber)

- R-Sport International in Portland http://yhst-26451710505916.stores.yahoo.net/rsiwiscfor24.html

- iPd http://www.ipdusa.com/prodtype.asp?CAT_ID=1142&numRecordPosition=0

I believe the RSI and iPd window scrapers are made of poron or neoprene (whatever is better, I get the materials confused). Also, iPd and RSI have YouTube installation videos.

The Dave Barton page shows failing factory exterior window scrapers. Roll down a window and if they feel stiff and / or have shrunkl away from the end of the back trim around the window, replace them.

If your 240 wagon has a rood rack, you may want to verify the roof rack seals, where the rack secure to the roof, do not leak. Few faster ways for a 240 wagon to rust if the roof rack seals leak, allow water to intrude, and you have rust inside the C-pillar (behind the rear door) usually on the driver side. Moisture intrusion, like 240 and 140s with moon roofs will collect behind the passenger front seat and can cause the floor to rust.

This may seem like a lot of work ....

You may want to remove the interior door card, or door panels, and clean the door interior, verify the power window securing hardware is torqued, as the hardware can loosen after 24 years or age and vibration. Once inside the door, you may want to clean the loose dirt, verify the drain hole at the bottom are clear, and use some sealant like Waxoyl or a heavy white lithium grease to displace moisture. You may find on the the inside of the door panel exterior the asphalt-like sound deadening material has fallen off the door and is clogging the drain holes. If so, remove it, along with accumulated dust and dirt. Check that the plates securing the window glass to the window regulator lift is not rusted and secure. You may also use this time with the door card removed to install better 4" (100 or 108 mm) front door speakers. (Please see my post history are to suggestion for better front door speaker install methods.)

Perform the same for the rear hatch or tailgate. Remove the carpet covered inner panel and inspect for dirt, rust, and such, and remediate.

Please take a close look at the rear hatch hinges. If not already replaced, the rear hatch side, after the hinge pin, of the hinge may rest on the roof surface a bit, or appear sagging. While the 240 rear hatch gasket is quite large and compliant, sagging rear hatch hinges can allow the rear hatch to drag the bottom lip on the rim as you open and close it.

You may want to remove the rear tire and inspect the area where the exterior panel meats the hump of the wheel well. Moisture intrusion and operation in salty winter environments can cause rust there. A location where Volvo are more susceptible to rust. The driver side on my 1990 240 DL is rusted out I discovered recently.

Apply heavy white lithium grease to all hinges, door catches, and the like; hood hinges included.

If you go to Ziebart, I hope they steam clean under your Volvo 240 before applying the sealing waxy undercoating stuff. They should also let you know if they find rust.

There's probably more, but I can't think of anything.

Questions?

Hope that helps.

Buttermilk MacDuffy's Tavern.
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I own three Volvo 240s, so, no worries. All with manual transmission.