Cross-member beneath tailgate

[Audrey Old]

Haven't had 240s for as long as 164s so unsure if there is a repair panel or replacement for the cross-member that is visible between the bottom edge of the estate tailgate and the bumper top - the one that always seems to go rusty.
Somebody said not an MoT fail, but rusty ones look so worrying!

Paul

[heckflosse]

I'm not aware of a professionally made panel, but it is relatively hidden and a functional repair should do. MOT wise, unless it affects the tailgate latch or is a sharp edge sticking out, can't see too much to worry about.

[Mike_Brace]

About 5 years ago I bought a panel from Volvo that fits the top part of this and I just made up pieces for the back end of the floor pan that is underneath.

You can see the piece still in black here:

[Jungle_Jim]

Hi all

Just for peoples' information, this replacement repair section is available. You'd think that Volvo would sell a few of these because this section probably rusts out on every 240 estate.

It's Volvo part #3528946 - and still orderable - Braydons are doing them for £76.50 - much cheaper than Volvo itself, despite being a Volvo part! Hopefully they can also find some of the clips to attach the chrome strips back which aren't an arm-and-a-leg.

This section is getting rusty on my 92 240, and I took it to a welder with a view to getting him to patch a few spots, and when we took the chrome strip off it was looking very crusty so he told me to find a whole replacement section.

Thanks Paul for starting this thread by the way.

Cheers
John H

[Derek UK]

If you're getting one of the Volvo panels can you put up some pics of it please. It might be something that can be fabricated fairly easily. Maybe a long bed bending machine, a guillotine and a bit of shaping will do it. A business opportunity for someone?
I know I really need one. The rust is hidden under the rubber but just showing. Unfortunately the water settles where the rubber seats on the section, hidden away under the edge of the hatch, and rarely has time to dry out between showers.

[Mike_Brace]

The Volvo panel curves up round the corners. Also it is not a straight piece across the rear it is curved - think of the shape of the trim. Good value from Volvo

[Volvodrivingbiker]

does this repair section include the bottom half underneath the bumper as it looks like two peaces to me although I've only looked from above

[Mike_Brace]

It is just the top part that you can see. The bottom part is the end of the floorpan but is easily repaired using sheet metal and the repairs can't be seen. The Volvo part makes getting the shape etc correct very easily.

[Jungle_Jim]

Hi All
Here's some pics of the replacement part as mentioned in this thread.

As you can see it replaces the part of the rear of the car which the tailgate catch is bolted to.

Before Xmas I was in a rush to get this problem dealt with, but as the welder has said, at this stage it doesn't matter if the relevant rot gets just a bit worse this winter because it'll be cut out and replaced.

Once this piece is welded in, I'll post any pics I have of the process and make a post about what rust protection I used to finish the job.

Thanks John H

[Jungle_Jim]

FAO Mike Brace
Mike one question about the silver 240 in the photo above which you repaired this section of: if your replacement piece was the same as mine, did you chose to cut it in half and only use the bottom half, leaving the section above which is attached to the tailgate catch? (because it looks to be silver while the new metal is painted black)

Just curious, and I guess we could consider the same option depending on the extent of the rust in mine.

Thanks again,
John H