1996 Volvo 960

Introduction:

The 1996 Volvo 960 is a mid-size luxury sedan known for its safety, comfort, and style. It was available with a range of engine and transmission options, including:

• Inline-5 2.5L with 170 horsepower and 166 lb-ft of torque
• Inline-6 2.9L with 201 horsepower and 210 lb-ft of torque
• 4-speed automatic transmission (AW70 / AW71)
• 5-speed manual transmission (M90)

While the 960 received praise for its comfortable interior and advanced safety features, it has also been subject to various issues over the years.

Engine

Inline-5 2.5L

• Intake Manifold Cracking:
  • Description/Symptoms: Development of cracks in the plastic intake manifold, leading to vacuum leaks, rough idling, and reduced performance.
  • Solution: Replacement of the intake manifold.
  • Estimated Cost to Fix: $500 - $1,000
  • Recalls: None Found
• Water Pump Failure:
  • Description/Symptoms: Failure of the water pump due to bearing wear, resulting in overheating and coolant leaks.
  • Solution: Replacement of the water pump.
  • Estimated Cost to Fix: $200 - $400
  • Recalls: None Found

Inline-6 2.9L

• Timing Belt Failure:
  • Description/Symptoms: Failure of the timing belt due to age or wear, leading to catastrophic engine damage if not replaced on schedule.
  • Solution: Replacement of the timing belt, tensioner, and water pump.
  • Estimated Cost to Fix: $800 - $1,200
  • Recalls: None Found
• Cylinder Head Gasket Failure:
  • Description/Symptoms: Deterioration of the cylinder head gasket, causing coolant and oil leaks, engine overheating, and loss of power.
  • Solution: Replacement of the cylinder head gasket.
  • Estimated Cost to Fix: $1,500 - $2,500
  • Recalls: None Found

Transmission

4-speed Automatic Transmission (AW70 / AW71)

• Overheating and Shifting Problems:
  • Description/Symptoms: Overheating of the transmission, leading to shifting problems, loss of power, and potential failure.
  • Solution: Overhaul or replacement of the transmission.
  • Estimated Cost to Fix: $1,500 - $3,000
  • Recalls: None Found
• Torque Converter Failure:
  • Description/Symptoms: Failure of the torque converter, resulting in shuddering, slipping, and loss of power.
  • Solution: Replacement of the torque converter.
  • Estimated Cost to Fix: $500 - $800
  • Recalls: None Found

5-speed Manual Transmission (M90)

• No Issues Found

Suspension

• Strut Bearing Failure:
  • Description/Symptoms: Wear or damage to the strut bearings, leading to noise, vibration, and reduced steering precision.
  • Solution: Replacement of the strut bearings.
  • Estimated Cost to Fix: $200 - $400
  • Recalls: None Found
• Ball Joint Wear:
  • Description/Symptoms: Wear or damage to the ball joints, causing clunking noises, loose steering, and poor handling.
  • Solution: Replacement of the ball joints.
  • Estimated Cost to Fix: $500 - $800
  • Recalls: None Found

Electrical

• Alternator Failure:
  • Description/Symptoms: Failure of the alternator, resulting in electrical problems, difficulty starting the vehicle, and eventual complete electrical failure.
  • Solution: Replacement of the alternator.
  • Estimated Cost to Fix: $300 - $600
  • Recalls: None Found
• Starter Solenoid Failure:
  • Description/Symptoms: Failure of the starter solenoid, causing difficulty or inability to start the vehicle.
  • Solution: Replacement of the starter solenoid.
  • Estimated Cost to Fix: $100 - $200
  • Recalls: None Found

Exterior

• Window Regulator Failure:
  • Description/Symptoms: Failure of the window regulator, causing difficulty or inability to operate the power windows.
  • Solution: Replacement of the window regulator.
  • Estimated Cost to Fix: $200 - $400
  • Recalls: None Found
• Door Lock Actuator Failure:
  • Description/Symptoms: Failure of the door lock actuator, causing difficulty or inability to lock or unlock the doors electronically.
  • Solution: Replacement of the door lock actuator.
  • Estimated Cost to Fix: $100 - $200
  • Recalls: None Found

Interior

• Dash Cluster Failure:
  • Description/Symptoms: Failure of the dashboard cluster, resulting in inoperable gauges and warning lights.
  • Solution: Repair or replacement of the dashboard cluster.
  • Estimated Cost to Fix: $500 - $1,000
  • Recalls: None Found
• HVAC Blending Door Actuator Failure:
  • Description/Symptoms: Failure of the HVAC blending door actuator, causing problems with temperature control and air flow.
  • Solution: Replacement of the blending door actuator.
  • Estimated Cost to Fix: $200 - $400
  • Recalls: None Found

Summary

The 1996 Volvo 960 has been known for a variety of issues, particularly with its engine, transmission, and suspension. The severity and cost of these issues can vary significantly, but some, such as timing belt failure, cylinder head gasket failure, and transmission overheating, can be major and expensive to repair. As with any used vehicle, it is important to research common issues and factor in the potential cost of repairs when considering the purchase of a 1996 Volvo 960.