5000 km Update!
Just as an update
I have just driven over 5,000 km (3,000 miles) since putting this car back on the road and as expected I have had a couple of hiccups as well as some upgrades.
Voltage Regulator
My rebuilt alternator had the voltage regulator came loose causing me to lose electrical charging. I guess the guy who rebuilt my alternator didn't tighten the two screws that hold the regulator to the alternator and as one of them completed backed out. Fortunately the car has a voltage gauge and I was able to notice the problem before my battery was completely drained.
Universal Joints
I replaced all three U joints on the drive shaft as well as ensured the shaft was installed in the correct balanced and phased positon. The car drives smooth with no vibration at highway speeds.
Alternator Pulley
I noticed my voltage dropping again followed by a ridiculous metal on metal sound coming from the engine. It turns out my trusty alternator rebuilder did not install the woodroff key so the pulley spun loose on the shaft. I was able to install a key and I have not had any problems since.
Gas Tank
I replaced the original, internally rusted gas tank with a good used one and after a few hundred miles it began to leak
. Needless to say I had to replace the tank with a new one I got from Cross Canada for about $200. Fortunately all of the clamps and hose were new so this didn't take a long time.
Engine Mounts
After a few weeks of use I notice the cheapo engine mounts I had just wouldn't cut it and I needed to replace my engine mounts with something a little more robust. I ended up going with the 240 volvo OEM diesel mounts for $50 from Tasca.
Muffler & Tail Pipe
The baffling inside my muffler had come loose and created an annoying ratting sound (Kind of like a vibrating heat shield). The tailpipe was fine but for $20 I wasn't going to try to wrestle it loose from the old rusted muffler so I bought a new one. I was able to get a muffler and Tailpipe from FCP for around $50!
Suspension Bushings
I replaced all the suspension bushings with polyurethane bushings from IPD. The original bushing were still in driveable condition but I figured after 30+ years it might be a good idea to replace them. This was a major PITA as some of the bolts were seized to the inner part of the bushing which resulted in me needing to burn out the old rubber and cut out the bolt. Has anyone noticed that if you buy the bushings individually from IPD they are cheaper then the whole kit?
Radiator
The day I was working on the bushings I noticed a little coolant on the splash guard so I traced where it could be coming from at sure enough it was leaking from the upper radiator port. I thought perhaps I didn't tighten the clamp so I tried to tighten it a little more and sure enough the plastic port broke. Fortunately I had a spare 2 core sitting around to keep me running while I keep my eyes open for an all metal 3 core.
Grille
Some one stole the grille off my 240 but I was able to get a replacement off of the form for under $50!
Wiper Motor
The wiper motor would at times, not shut off or return to proper home position. I had a good used one and since then have not had a problem.
Upgraded Lighting
I upgraded the lighting system to use the H4 type light bulbs for low beam lights. I also got some white H4 bulbs that really make early morning driving a little more visible. A huge improvement over the old style sealed beam lights.
LED Dash Lights
I changed the instrument panel and dash lights to LED lights and they have really brightened up some rather dull gauges.
Things I am thinking of doing. . . . . . .
B21FT Cold Air Intake
I have been thinking of performing this upgrade but I can't seem to find 2.75" ID PVC piping anywhere. I have looked at possibly using silicone piping to do this but it comes out to around $30.
Wheel Spacers
I have noticed that the rear wheels sit a little to far in the to the well (for my liking) and I was thinking of getting some 1" spacers to push them out a bit. I am curious how this would look or if it would be at all doable without rolling the fenders. Any input would be appriciated.
The above list of repair items should be an eye opener to anyone that wants to take a 30+ year old car and use it as a DD. I was prepared for additional repairs but I think a lot of people buy $1000 Brick and expect it to run forever without sinking a buck into it. These cars will run for a long time but the need to be maintained.
Below is a current photo of the car