Hi Eric G.
I know your pain. I have not had a set of stabilizer bar links installed yet but I see your point. The design is not very robust. You might want to try to call IPD and ask to talk to one of their technical specialists. I installed their anti sway bar in my 1999 V70 XC and was having a problem with keeping the bushing lubed. A technician got on the phone and we discussed the problem and came to a solution. IPD might know something or someone who sells a better bar.
The other issue you have is multiple installation of the same part. I know how you feel! On my V70 XC I have had 4 widow switches replaced (the driver switch 3 times), 2 upper engine mounts replaced and 3 turn signal light/socket replaced. It took the power of the US Department of Transportation to get Volvo to fix the turn signal problem here is the US.
The issue I see with Volvo is that they as a company do not do Value Engineering (i.e. they do not redesign/examine parts to fix reoccurring problems found at the dealers). I see no continuos improvement in the product once it comes on the market. To make my point all you have to do is look at the turn signal light bulb/socket issue. Volvo install the light/socket in the 1998, 1999 and 2000 V70s. They knew that there was a problem with the light/socket back in 1998. For 3 years they kept installing the same light/socket knowing that it was going fail! The problem was so bad that IPD was selling a light bulb kit upgrade to fix the problem that Volvo was ignoring! Now that is bad when a third party company can make money because a car manufacture will not fix its problem. I can go on with several other examples (upper engine mount, ball joints, window switches, etc….). I wonder about the issues I know nothing about because my car has not reached that mileage point (transmission issues due to burning fluid, transfer case gears being chew up due to tire size not being the same from front to rear and so on….). It is enough to keep you up at nights!
I do agree with you my 1999 V70 XC is not a keeper. When I bough my V70 XC I had high hopes and a good feeling that I was buying a quality car. What I got was a poorly engineer car and a Car Manufacture who will not back its product. I have 1-½ years or 24kmiles left on the warranty. At that time I am planning to dispose of my nightmare and buy a real good car. One I can keep for 10 years.
Good luck, Best wishes,
Steven---
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