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92 240 wagon elec gremlins

H

haroldburbank

Member
Joined
Jul 6, 2024
hello, was night hwy driving. dry conditions, suddenly engine stumbled each time i switched from low to high beams. drove 100 more miles. engine began to stumble regardless of lights. turned off heater blower. stumble 'improved'. drove 50 miles. engine lost power on hill. did not quit. pulled over. idled fine for 15 minutes. resumed highway speed. in 10 miles engine badly stumbled. steadily losing power. got to a truck stop. shut down motor. would crank slowly after but not start. towed home. battery not dead but weak. plan today: 1. test: battery. it's @ 5 years old. may have bad cell. 2. test alternator. have spare battery. will install. if charging obviously old battery the issue. 3. remove alternator and inspect voltage regulator. installed a reman'ed bosch 100 amp alternator @ 7 years ago. replaced the regulator @ 3 years ago. maybe it's due. would not hurt to replace. have i missed any obvious check points for my symptoms? fuses, relays etc?

note the car has over 450k miles. it's been loved to death. use it as a truck today. rusty floor, rockers, 1 fender all bondo. 1 trans mount probably should be welded. thus 'universal' rust issues. i suspect rusty grounds can cause my elec issues above. checked and cleaned all engine bay grounds can see 2 months ago. i am sure i missed 1 or 2. where do they hide on fender walls? others? anyone have pics?

i have an old saab 900 sitting in my driveway. read that alternator can be used in volvo 240. correct?

AND has anyone worked with carbon fiber on 240 floors, key frame areas etc? i cannot weld but own a cheap harbor freight wire welder (need lessons). i do not think many welders in CT will weld my car. i have built boats with all manner of resins. i am willing to experiment with carbon fiber to save this car. the engine runs perfectly. oil changes every 3k. would hate to scrap the car. been great to my family and me.

thanks in advance to this terrific forum. you have taught me a lot already. look forward to your comments.
 
The symptom you describe is a alternator that isn't charging. It may have an issue with the charge light circuit. If that doesn't operate then you don't get charging. I would test the alternator with the car warmed up after running awhile.

I never heard that a Saab alternator will work. But you can compare the mounting points and see if they work.
 
Under the car, there's a short ground cable that goes from the body of the alternator over to an engine block bolt. Check that cable for corroded ring terminals, and that it's making good contact to the alternator body and block.

You can get a cheap USB charger with a voltage display on Amazon - for example
"Strong earthquake bumps keep charging"
 
thanks to the commenters. i charged the battery 2 hours. car fired right up. alternator appears to be pushing 13 volts at idle (voltmeter). there are 2 belts on the alternator,. to my surprise both are rather loose. at idle they appear not to slip but am betting at highway speed they were slipping leading to battery discharge and described symptoms. will tighten, measure voltage, test drive fast, and report back. good news is the regulator appears fine.

will check all alternator grounds per advice. thanks.
 
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