I removed the alternator to replace the bushings and cracked the darn power insulator. The insulator base is intact and I think I can "make shift repair" the broken part of the insulator with JB or maybe just silicone. The arc distance I think is too great even though the nut is close to ground but I would be concerned with electrical creeping when the broken surface gets dirty. Maybe JB weld the plastic insulator back on and goop on some silicone around it.

The make shift repairs you find: There was a perfectly sized washer under the front alternator mount bushing, odd for Volvo to put this in, "ahhh", said I 30 seconds later after I inspected the original bushing, it was added as a fast repair to help straighten the belt alignment.

Right or wrong the these two bushing will be now be aluminum. (Another makeshift repair?) The adjuster mount with the third bushing will remain rubber due to almost no deformation. Say I'm wrong, I'll use poly, but for now all I have is alum and rubber.

Time to replace the brushes too. Looking for an old post I remember.

Then to yet another water pump mushroom gasket.

Tom

PS,the Brickboard search function does not work for me but google search does. Used "Brickboard volvo 240 alternator brushes replacement" as the search criteria. I could have added "RWD - " Thanks again Art B.