1991 Volvo 240 — MOT failures & pass rate
838 MOT tests on the 1991 Volvo 240 are in this dataset, and 75.3% of them passed. Against all cars of a similar age (22.4% fail rate), the 1991 240 comes out 2.3pp worse. Failures cluster in lighting & signalling, suspension and body, structure & corrosion.
What the MOT record shows
One area stands out: lighting & signalling, recorded in 15.9% of tests against 11.1% for the next-worst category.
At component level the recurring items are component mounting prescribed areas, headlamp aim and pins and bushes — component mounting prescribed areas alone was recorded 74 times.
Condition tracks the odometer closely. Failures run at 13.6% in the 60-90k band and 28.5% in the 150k+ band, a 14.8-point spread — more than double.
Suspension is the most common advisory, noted on 33.2% of tests — work that passed today but is likely due soon.
The trend is improving — the fail rate fell from 26.7% in 2021 to 19.9% in 2025, as the worst-kept examples leave the fleet.
How it compares
Top failure categories
| # | Category | % of tests affected | Tests |
|---|---|---|---|
| 1 | Lighting & signalling | 15.9% | 133 |
| 2 | Suspension | 11.1% | 93 |
| 3 | Body, structure & corrosion | 8.3% | 70 |
| 4 | Brakes | 7.2% | 60 |
| 5 | Visibility | 5.9% | 49 |
| 6 | Steering | 5.4% | 45 |
Most common specific failures
The exact components most often recorded as failures — more specific than the categories above.
| # | Failure item | Times recorded |
|---|---|---|
| 1 | Component mounting prescribed areas | 74 |
| 2 | Headlamp aim | 53 |
| 3 | Pins and bushes | 44 |
| 4 | Stop lamp | 41 |
| 5 | Washers | 37 |
| 6 | Position lamp | 35 |
Top advisory categories
Advisories aren't failures, but they flag work likely needed soon — useful when budgeting.
| # | Category | % of tests with advisory | Tests |
|---|---|---|---|
| 1 | Suspension | 33.2% | 278 |
| 2 | Brakes | 24.5% | 205 |
| 3 | Body, structure & corrosion | 17.7% | 148 |
| 4 | Other defects | 17.4% | 146 |
| 5 | Tyres | 15.5% | 130 |
| 6 | Emissions & environmental | 15.2% | 127 |
Failure rate by mileage
Higher-mileage cars tend to fail more — often the most useful guide to real condition.
| Mileage band | Tests | Fail rate |
|---|---|---|
| 60-90k | 88 | 13.6% |
| 90-120k | 156 | 21.1% |
| 120-150k | 199 | 27.1% |
| 150k+ | 365 | 28.5% |
Trend over time
| Dataset year | Tests | Fail rate |
|---|---|---|
| 2021 | 210 | 26.7% |
| 2022 | 182 | 28.0% |
| 2023 | 156 | 23.7% |
| 2024 | 154 | 23.4% |
| 2025 | 136 | 19.9% |
What to check before buying a 1991 240
The failure pattern for this year is specific enough to inspect against: lighting & signalling accounted for 15.9% of tests. Start there.
- Lighting & signalling (15.9% of tests): Often a cheap bulb, but persistent issues can mean wiring or corrosion in the units. Typical repair: £10–£150.
- Suspension (11.1% of tests): Worn drop links, bushes, springs or shocks — listen for knocks over bumps and check for uneven tyre wear. Typical repair: £150–£450 per corner.
- Body, structure & corrosion (8.3% of tests): The one to take seriously on older cars — corrosion to structural areas can be costly and is an MOT failure. Typical repair: £200–£1,500+.
Repair costs are rough UK ballpark ranges to set expectations, not quotes — actual prices vary widely by car, parts and garage.
Frequently asked questions
How many 1991 Volvo 240s pass their MOT?
75.3% of the 838 1991 Volvo 240 MOT tests in this dataset passed — a 24.7% fail rate.
What is the most common MOT failure on a 1991 Volvo 240?
Lighting & signalling, recorded in 15.9% of tests, followed by suspension (11.1%).
Does the 1991 240 get worse with mileage?
Its MOT fail rate rises from 13.6% in the 60-90k band to 28.5% in the 150k+ band.
Methodology & source. Based on 838 MOT tests. Dataset: DVSA MOT testing data (2021,2022,2023,2024,2025). Data last updated 2026-07-27. Figures reflect MOT-testable defects only — read the methodology for how these are calculated and what they don't measure.