I've had a hot no-crank no-start problem with my 1989 740 GL and had replaced all the usual suspects (RSR, FIR, crank angle/RPM sensor) and the ignition switch, but still had the problem recurring. Testing showed large intermittent voltage drops across the positive battery cable, so I decided to replace the cable.

This evening we pulled off the positive and negative cables and slit the sheath binding the two together. Lo and behold, the insulation on both cables was worn almost all the way through (to the point that the wiring was showing in a few spots) and the positive cable had a large crack in the insulation at the bend. The positive cable also showed signs of wearing through at the point where the cable comes off the cross member under the A/C compressor. I had initially intended to only pull the positive cable since it was showing signs of wear and cracking at the crimps on either end, but now I've got to get a new negative cable as well. These were most likely the original cables and the car currently has 325,000 miles on it.

I'm just glad that I found this out before I had a car fire.

Beth M.
Daily driver: Silver 1989 Volvo 740 GL wagon

Have you had a dealer or some other repair shop check your car for recalls?

When we bought our '88 745 GLE, our local shop told me that my car had not had its battery cable recall - my dealer repaired it for free.
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'96 855R,'64 PV544 driver, '67 P1800 basket case, '95 855, '95 854, the first three are mine, heh, heh, 485,000 miles put on 9 bricks

I had never asked about recalls, but I avoid dealerships whenever possible and hadn't asked my mechanic because I checked in general for recalls when I got it and only found the seat belt labeling and usage recall. Now that I've searched more intensively, I've found the battery recall, but it's really a moot point now, since I've acquired the redesigned cables and bracket and done the installation myself. I'm really surprised that the original owner hadn't already had this taken care of though, since he was fairly scrupulous in his maintenance of the car.

If you're interested in seeing the damage and the replacement part, I've posted the links to pictures in another thread.

Beth Mashburn
1989 Volvo 740 GL Wagon -- daily driver

Was that an actual recall or just a service bulletin? All I see is TSB 37-702 "Battery Ground Cable" dated Nov/90 instructing shops to re-route the ground cable upon battery replacement. This was only covered during the New Car Warranty period. In any case, glad you caught it.
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Dave -940's, prev 740/240/140/120 How time flies when you're having fun

I found the following info through Carfax:

Recall date: Not reported
Units potentially affected: 49,397
NHTSA campaign number: 96V085000
Defective part or component: ELECTRICAL SYSTEM:BATTERY:CABLE
Description: THERE IS THE POSSIBLILITY OF EXCESSIVE CHAFING OF THE INSULATION OF THE POSITIVE AND NEGATIVE BATTERY CABLES. THIS CONDITION CAN LEAD TO A SHORT CIRCUIT IN THE VEHICLE. DEALERS WILL INSPECT THE CABLE HARNESS AND, IF NECESSARY, CORRECT.

Considering that it says "if necessary" I would assume that it wasn't a mandatory recall and would be considered as mechanics did regular inspection maintenance

Beth Mashburn
1989 Volvo 740 GL Wagon -- daily driver

Several years back there was a recall notice on some of the 740's to correct a problem with the battery cables chafing on some metal structure, creating a fire hazard.

That chafing was the exact problem that I had. I was able to purchase new cables and the negative cable included a new version of the frame that holds the exhaust hose that leads to the air cleaner box. The new version of the frame has a channeled bracket section that holds the negative cables together, then loops one cable down to the power steering pump bracket ground. This keeps it away from the positive cable, but you also have to replace the old positive cable bracket with a slightly smaller one (like the rest of the brackets that hold it across the crossmember). The only problem then is that the positive cable has a fair amount of slack to it coming up from the crossmember to the battery. We solved this by zip-tying the pos cable to one of the a/c lines that crosses that area.

Beth Mashburn
1989 Volvo 740 GL wagon 300,000-some-odd thousand and still going.

from the FAQ: ... a direct short where cables pass under engine. Volvo neatly bundles both cables in a plastic sheath. Unfortunately too tight against bottom of engine and cut through, often at the clamp securing them. This is all too frequent in pre-1990 cars. A new battery and cables cured the problem. Volvo later issued a recall for battery cable chafing.
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See the 700/900 "FAQ" at the menu bar top screen left side.

Yep. That was exactly what was happening. Fixed now with new cables and the retrofitted neg cable bracket.

Beth Mashburn
1989 Volvo 740 GL Wagon

Was there a lot of corrosion,or did this look like fatigue or abrasion?
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See the 700/900 "FAQ" at the menu bar top screen left side.

There was some corrosion at the crimps on either end of the pos cable where the insulation had cracker, but the damage underneath was obvious rubbing abrasion in the bundled sheath, right at the first clamp. I've got a fair amount of oil blowby down there from old leaky gaskets (future project). I've got pictures of the cables after I pulled them and of the neg cable with the old and new brackets for comparison. I'll try to get those pics uploaded later this evening or tomorrow.

Beth Mashburn
1989 Volvo 740 GL Wagon -- daily driver

Yep, that's the precise area addressed by the recall notice for pre-1990 cars. Chaffing against the clamp and subframe parts.
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See the 700/900 "FAQ" at the menu bar top screen left side.