The Volvo 240 is one of the most iconic vehicles in Volvo history and one of the longest-produced car models ever made. Produced continuously from 1974 to 1993 (20 model years), approximately 2.86 million Volvo 240 and 260 series vehicles were built worldwide. The boxy upright styling, the famous brick-like profile, and the reputation for safety, longevity, and reliability made the 240 the quintessential US-market Volvo of the 1970s and 1980s. Associated with educated middle-class buyers, doctors, and college professors, the 240 became an enduring cultural icon. Body styles include the 4-door sedan (240 DL, GL, Turbo trims), the famous 5-door wagon (one of the longest-lived station wagon models ever), and 2-door variants in early years.
The brake booster is a vacuum-assisted servo that amplifies driver pedal force using engine vacuum, providing the power-assisted braking that makes modern cars easy to stop without excessive pedal pressure. On the 240, the booster mounts to the firewall with the master cylinder bolted to its front face. The booster receives vacuum from the intake manifold through a rubber hose with a one-way check valve to retain vacuum even when the engine is off. When the brake pedal is pressed, internal valves admit atmospheric pressure to one side of an internal diaphragm, which uses the pressure differential against engine vacuum on the other side to multiply pedal force into the master cylinder. The 240 sister vehicle 260 series (1974 to 1985) used essentially the same brake booster with V6 engine adaptations.
The most common reasons 240 owners replace the brake booster are: internal diaphragm leak causing a hard or stiff brake pedal even when the engine is running and producing vacuum (the most obvious symptom), check valve failure causing the booster to lose vacuum within seconds of engine shut-off (test by pumping the brakes after stopping the engine, should have at least 2 to 3 power-assisted presses), hissing sounds from the booster when the pedal is pressed (vacuum leak from torn diaphragm or worn poppet valve), or external body rust at the firewall mounting points after 30+ years.
Less commonly, the booster can be damaged by extended operation with brake fluid contamination if the master cylinder seal fails internally (allowing brake fluid into the booster through the pushrod seal, causing internal damage). The 240 brake booster is relatively reliable when the brake system is maintained properly, but after three decades of service most original units have reached or exceeded their service life. Our used OE booster at $89 saves significant money over a $180 to $350 new replacement when combined with proper brake system service.
| Detail | Description |
|---|---|
| 240 NA (Naturally Aspirated) | Standard vacuum booster for B21A, B21F, B23F, B230F naturally aspirated I4 engines. Single diaphragm design. Direct vacuum connection to intake manifold. |
| 240 Turbo (1981 to 1985, 1988 to 1991 returning) | Same physical booster as NA 240 but with check valve sized for turbo intake characteristics. Turbo engines produce less vacuum than NA at boost, so check valve retention is more critical. Confirm year and turbo status when ordering. |
| 260 V6 (1974 to 1985) | Different vacuum characteristics from PRV V6 (Peugeot-Renault-Volvo joint V6 engine). Booster is similar but vacuum hose routing and check valve differ. Confirm 260 V6 application when ordering. |
| Detail | Description |
|---|---|
| INCLUDED | The complete brake booster assembly with internal diaphragm, valves, pushrod, mounting studs for firewall, mounting studs for master cylinder, vacuum check valve. Sealed unit ready to install on the firewall and accept the master cylinder. |
| NOT INCLUDED | Master cylinder (separate part), vacuum hose to intake manifold (replace if cracked or hardened, often a good idea after 30+ years), mounting nuts (reuse originals or source new from hardware store), brake pedal pushrod adapter, brake fluid, brake lines. |
| Tools You Need | Metric and SAE socket sets (240 uses mostly metric but some imperial), brake line wrenches for master cylinder connections, brake fluid catch pan, vacuum gauge for testing (optional but helpful), torque wrench, jack and stands or lift. Bench bleeding the master cylinder before reinstalling is recommended. |
The Volvo 240 brake booster is compatible with the following 240 and 260 series variants. Confirm year, series, and engine before ordering.
| Detail | Description |
|---|---|
| Volvo 240 DL Sedan (1974 to 1993) | Standard trim 4-door sedan, NA I4 engines |
| Volvo 240 GL Sedan (1974 to 1993) | Higher trim 4-door sedan, NA I4 engines, more options |
| Volvo 240 Turbo Sedan (1981 to 1985, 1988 to 1991) | Turbocharged variant with B21FT or B230FT engine |
| Volvo 240 DL Wagon (1974 to 1993) | The famous boxy Volvo wagon, 5-door, NA I4 |
| Volvo 240 GL Wagon (1974 to 1993) | Higher trim wagon, NA I4 |
| Volvo 240 Turbo Wagon | Turbocharged wagon variant |
| Volvo 240 2-Door (1974 to ~1984) | Less common 2-door variant, mostly early years |
| Volvo 260 Sedan (1974 to 1985) | V6 variant with PRV engine (B27/B28/B280) |
| Volvo 260 Wagon (1974 to 1982) | V6 wagon variant, rare in US market |
Not compatible with Volvo 140 series (1966 to 1974 predecessor of 240) which used a different booster design. Also not compatible with Volvo 740/760 (1982 to 1992 sister/successor) which used updated booster design with different mounting pattern. Volvo 940 (1991 to 1998 direct 240 successor) used a different booster too. Some 240 boosters interchange with 740 of certain years but always confirm part number. Call (240) 301-0095 if uncertain.
Not sure if this Volvo 240 brake booster fits your car? Call (240) 301-0095 with your year (1974 to 1993), series (240 or 260), body style (sedan, wagon, or 2-door), and engine code (especially important between NA and Turbo, and between I4 and V6 on 260). Our team confirms the right booster for your specific 240 or 260 application before we ship.
This used OE Volvo 240 brake booster has been bench-tested and inspected before listing. Quality control includes:
Each booster ships with a label identifying the donor vehicle year, engine, and turbo status. We recommend replacing the vacuum hose to the intake manifold during install if your hose is cracked or hardened (a $15 part that prevents check valve issues). Master cylinder bench bleeding before reinstallation is recommended for proper brake system performance.
To file a claim, contact us within 15 days of delivery at (240) 301-0095 or support@vazautosolutions.com with the original order number, photos of the installed booster, vacuum gauge readings if available, and a description of the symptom. We process most warranty replacements within 48 hours.
