All maintenance & repair work except starter rebuild were done by authorized Volvo service centres per Volvo maintenance and inspection schedules, from brand new.
Listed below are exceptional repairs beyond routine maintenance, tire replacement and body work, costing over $90 CAN for parts & labour:
90 (90,000 km:left side mirror defrost in-op
108: headlight glass broken on highway
111: front stabilizer link replacement
119: engine rear crank seal failure
121: transmission coolant line failure, transmission in-op
128: rear spring rebound rubber replacement
137: front stabilizer link replacement (warranty from 111 job)
143: left side mirror defrost failure
148: front brake rotor replacement
153: right lower ball joint replacement
162: rear tailgate wiper transmission failure
166: front stabilizer link replacement (not covered by warranty from 137 replacement - missed by 11 days, but Volvo Canada would not budge)
169: console transmission lever indicator light failure
169: rear brake rotors replaced
173: starter rebuild
175: sudden brake hose failure at l/f wheel, loss of brakes
175: left front axle seal failure
175: engine mount torque arm bushing failure
176: head gasket failure.
Excellent ergonomics and safety features. Goes well in snow with 4 snow tires.
Great utility and comfort, but reliability disappointing and repair costs are expensive.
Rear crank seal failure and transmission coolant line failure had high potential for serious engine/transmission damage.
Brake failure had high accident potential.
No serious rust yet after 7 winters of heavily salted Canadian roads.
Is the brake problem experienced by other owners as well? I was looking at one of these used, but do not want to put my son in an unsafe car.
I run a taxi company in the UK, and we used to have a fleet of 12 Volvo 850s of varying ages (1993-1996) and mileages (one reached 290,000 miles by the time it was sold).
Over the time the company had the cars (which was from new or nearly new until 150,000 miles minimum), I never experienced the sudden brake failure problem with any of the cars. And they were taxis and worked damn hard.
Generally speaking, they were very reliable; most of the work that was required was standard service items or items that were expected to have a limited life. Had a couple of automatic transmission failures at high mileage, a turbo failure, some suspension replacements and new clutches at 100,000-125,000 miles and a throttle housing replacement. Considering that's over 12 cars, it's not bad.
One thing that always wore out quickly on these cars was the tyres. The front tires always used to wear slightly unevenly, but that's a consequence of a deliberate Volvo design feature.
And they're safe cars too - one of them hit a narrow concrete bridge support at 80mph. The front passenger was bruised, but otherwise unharmed and the driver only received a broken leg. I use the term 'only' because 18 months later a similar accident occurred in the same place. Similar speed, different car of a similar age and size - unfortunately this time there were two fatalities.
Judging by all the problems you've had with your Volvo 850 and how uncharacteristic your problems are compared with other owner reviews of the same car, I have a feeling that your Volvo 850 may have been a possible rebuilt salvage without your knowledge. I am quite knowledgeable with the 850 and know of common problems experienced. Most of the problems you experienced are not at all common for this car. Rear main seal, O2 sensor, knock sensor, shifter selector failures, and power seat failures are all common problems on all 1993-1997 850s. Most 850s experience these problems sooner or later. I'm sorry you got the lemon of the bunch because the 850 is better than the average car of the '90's in terms of safety, reliability, and longevity.
I experienced problem in opening the gas cap when I try to refill, especially when there is line behind you and you have to search the manual to open it. And the manual has instructions about this! That means the manufaturer knew sometimes you cannot open the gas cap! What a design!
Update to the list
First: a retraction - no head gasket fail at 176 - happily it was an uninformed misdiagnosis. Sincere & humble apologies for the inaccuracy.
184 A/C fail - replace a/c receiver dryer and o-rings
186 Left front brake caliper replacement
186 Liftgate gas struts replacement
194 Thermostat required replacement
198 Right front brake caliper & all 4 rotors replaced
199 Failed idler pulley - replacement
201 Steering system universal joint worn out
205 Right headlight wiper motor required replacement
205 Steering stabilizer links worn out (this regular event has become part of the mtce. budget)
213 Exhaust manifold and muffler require replacement.
Despite its faults, the car was recently treated to a new set of Michelin tires, new windshield and full paint job. In an agonizing way, it remains a joy to drive.
Author's note on the brake failure mentioned in the main post: The flexible rubber hose going to the left front brake broke. If I recall correctly, the breaking point was just above a protective metal braiding. The root causes of this fail were not determined so it may have been the result of any number of events dealing with the initial design, wear of the rubber from age and continual flexing, damage from objects (stones, etc) on the road, and/or incorrect servicing. I have not seen this problem mentioned on any other Volvo sites so consider it a rare event.
I purchased a 850 wagon last year here in Calgary Alberta Canada. It had 177,000km. Everyone assured me that this is a longevity vehicle. Since that time I have replaced the following totaling $8,000 CDN in repairs.
Rear latch supports.
Rear latch panel.
Interior light dome.
Breaks fully replaced.
Transmission seal.
Heating sensors.
Heater
Airbag (it rotted out)
Cooling reservoirs.
Faulty headlights and wipers.
Faulty heated seats.
Steering column
Leaky seals and gaskets
faulty sensors and regulators
And many unknown vibrations that lend the vehicle to a common shake rattle and roll feel.
I purchased this vehicle to replace the Durango so my 16 son could be safe. Yet I am left with the sour taste that Volvo is in fact an lower than average car manufacture.
Brian.
I had a 1995 850T Wagon for five years and loved it! As a musician, I needed the cargo space and didn't want an SUV. In the matter of two years I put over $2600 in repairs: fuel pump, rear brake calipers, flame trap, tires...etc. at 150,000 the transmission went (saddest day ever!). Now with other repairs, altogether $6,000 + I am sad to have to get rid of it. Smooth, fast and reliable car: Volvo for life.
I take exception with the blanket implication that the Ford Taurus is unreliable. It really depends on which models you are writing about. Those built before 1996 were VERY reliable cars. I have had 4 of these cars and I sold three of them after they had 200k plus. One that I sold to a friend now has 260k and I was not a stickler for maintenance at all. Those after 96, with the new design and the Mazda transmission have a lot of problems from what I understand. Also, the cars with the 3.8 engine have a few more problems. Unfortunately, I don't have one of these great cars now though. I could really use the SW in a 1993 to 1995 model with low miles.
I own a 1995 850 GLE wagon 5 speed manual and I must say it's a great car, excellent on gas and reliable. Also it's built like a tank.
Beside the routine brake work and oil changes, I never had any problem with it considering I drive like a crazy.
Did I mention that it has 315.000 Kilometers...
Brian:
The issues you describe may not be a fault of the manufacturer. It is very possible that the car has been in an accident (or 2) in its lifetime. With older cars, electronics die and need replacement.
I encourage only to lay blame evenly, not all on Volvo.
~RE~
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