Just finished the brake booster R&R in a '93 with cruise and it wasn't that bad of a job. Of course, no job on a 240 seems that bad if you keep in mind the last time you replaced a blower motor.

What I discovered:

Question 1 - I bought a rebuilt booster at Advanced Auto for $116 + core. It arrived well-packed and complete with a new check valve already in place. If there was a country of origin on the booster or box, it escaped me. The only thing wrong with the rebuild was that the accordion boot and a felted filter around the actuating rod were not seated properly. Other than that, it LOOKED good and performed properly during a shakedown run. Sure as hell cured the hunting idle symptom.

Question 2 - When I first looked over the task of undoing the 4 brake booster mounting nuts under the dash, I thought that if I didn't remove everything in the way, I would probably spend more time trying to work around all that stuff. At least, that has often been my experience, wasting more time trying to save time. In the end, the only things I had to remove were the knee bolster and the footwell nozzle on the heating duct.

There is an fairly unobstructed shot at three of the nuts, but the upper right nut is buried deeply within the horrors under the dash. Fortunately, a socket on the end of a long extension (about 15 inches) can be carefully threaded from outside the dash through the jumble of stuff, and brought to engage that upper right nut; it does take some acrobatics to get an eyeball on the nut. The extension has to be withdrawn gingerly so that the socket is on snagged off its end only to end up god knows where, but other than that, it's no big deal.


Rich

Rich,

I replaced mine about 9 years ago with a rebuild from Advance AP. It has done a fine job so far. Good luck with the install, you will need to go to your chiropractor afterwards!
--
93' 240 Classic Wagon 220K & 92' 740 Wagon Regina/Rex 90K

Hello Rg,

Earlier this year, I finally replaced the brake booster on my 93 green sedan. I had replaced damn near everything on the car that could have caused a loping idle to no avail. And as you experienced, the loping idle and in my case even some stalling occurred when the car was cold and the brakes were applied, typically at the first stop sign or light once we left the driveway.

A couple of years ago, I replaced the booster with an earlier model booster. You don't want to make that mistake. Doesn't work properly. Brakes are so touchy as to make them dangerous. So I gooped the intersection of the two halves with silicone in the hopes that might solve the prob and put the original booster back on. And to some extent it did, but the loping came back a year later, as I recall.

You should also check the brake vacuum hose. Even though it's quite helfty, I'd still check it and the checkvalve for leaks, maybe applying some grease to the booster bushing where the checkvalve is inserted. You also indicated there's some "hissing" and you should probably verify where that's coming from before you change out the booster.

Since that time, a 92 showed up at the local JY and I pulled the booster and replaced my old unit and all seems to be well. From my perspective, I'd go the JY route. There's also a bunch of gents that frequent the BB that could prob get you a late model booster for $50 or so. I believe they rarely go bad, as I have had three other 93's without a problem.

Lastly, be careful changing out the booster as I managed to bend the support bracket for my brake switch which caused some consternation.

Good luck,

Marty Wolfson

Proud member of the 300K club

Hi,


Snag this! NOW!

http://www.ebay.com/itm/Volvo-240-260-vacuum-brake-booster-NOS-1229336-Bendix-/250975615676?pt=Vintage_Car_Truck_Parts_Accessories&vxp=mtr&hash=item3a6f4ffabc


Goatman