Lumbar supports are a pretty easy fix. I've fixed them several times, but only the first time did I buy the Volvo repair kit. You don't need it.

The weak element in the lumbar supports is that pair of skinny wires which connect the seat frame to the little seat springs. The rest of your lumbar components are probably OK. On my seats, I've widened the holes in the seat frames and plastic pieces so I could use heavier wire in place of the original thin stuff. I think you'd find baling wire and coat-hanger wire to be too soft. I've had the best success with some heavier gauge galvanized fence wire.

If you leave it unrepaired, there is a chance the little broken wire will poke through the back of the seat cover. I've always removed my seats to do this repair, but I suppose it is possible to fix it with the seat in the car. There is no need to cut the seat cover--just make it loose at the bottom and roll the cover up. My other tip is to quit the hog rings and use nylon cable ties instead.

Good luck with it!

When I had my seats reupholstered, the guy built in a non-adjustable lumbar support that has worked well. He took a couple of heavy nylon straps about three inches wide and fastened them across the seatback frame then padded them nicely.
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Thanks for all the help. DougC 1981 242, IPD bars and Turbo wheels, M46 :::::: 1993 245, B230 NA L-Block, M47, Turbo bars::::::1984 760, B23FT, M46

Many americans are fat, but I am a fit, slim 170 pounds. At my 6'3" stature, I am not the cause of my seats failures.

Check out IPD. They offer a spring kit for the bottom, a lumbar rebuild kit for the back, and seat heaters for both. They don't offer a diet kit for our lard a**es.

Bill

The seats were well made. I think the problem is Volvo's engineers never imagined possible the volume and mass of the typical American car occupant. However, 15-20 years, when 240s were in their prime, Americans were smaller, so maybe my hypothesis is invalid.

http://www.ipdusa.com/Volvo-200/Interior/Lumbar-Seat-Repair-Kit/p-69-262-637/