Alternators off pretty much any 240 or 740 should fit in without much modification. If you want higher output some of the later models had higher output alternators(100 amps on some I think). If you have a turbo you might have some problem getting larger alternators in because of the turbo. If you are really down on Bosch alternators, I think turbobricks has some info on putting GM alternators in. But I would stick with Bosch myself, since they are very reliable. Yours probably only needs new brushes.

How do you know it's not just the regulator? It's easier to check/change that then to pull the whole alt for nothing. See archives. Re power, how much do you need? Is your amp huge?

Wiring connections:
1st, disconnect the battery cables.
1 large red wire for the voltage output. 10mm nut.
1 tiny red wire for the dash warning light. push-on spade lug.
1 ground wire to a stud on the case. 8mm nut. I think mine was a blue wire.
1 adjuster locknut: 13mm, right under the water pump pulley. Just loosen it for now.
1 tensioner bolt- 10mm, really long. Loosen it 300 turns or until you can get the belts off easily
1 Looooong bolt for the bottom 2 brackets. 12mm or 13mm. YOu need a wrench on each end of it.
I would replace the rubber bushings that the long bolt and the adjuster are mounted with. They're only a few bucks. Once lined up, they go in easily. I did have to tap mine to seat them. FCP Groton sells them, they'er called "accessory bushings".
As the book says, installation is the reverse of the above. Carefully inspect the alternator wiring while it's out, and fix anything that's crunchy.
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Rob Bareiss, New London CT ::: '87 244DL/M47- 221K, 88 744GLE- 202K, 91 244 181K, 88 244GL 145K

Very easy Matt. Just make sure and disconnect the battery cables, take all alt. wires off (might be good to clean them if they look bad). Loosen your v-belts, undo you alt. bolts and it's all good to go. Replace w/ your new or good used alt. I have a bosch in my '85. No problems with it (besides replacing the voltage regulator once). This may be a good time to check that out also since your dealing with the alt. There are 2 screws you unscrew to check the length of the volt. reg. prongs. You may need to crawl under the Volvo to remove some of the alt. mounting bolts, but that's ok... it's not that bad. I just use a good size piece of scrap carpet. Sorry I wasn't able to answer your other questions. Have a good one..
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Michael 'Street'... one AZ '85 244DL 189K miles