When I owned rear wheel drive Volvos, repairs on the front end were non existent. With my 850, anti-sway bar links and transmission torque mounts are the only items ever replaced that were possible culprits of clicks and pops as the car moved forward.

I've had my 2004 S60R for 6 years and haven't had any issues besides the normal repairs that come at certain mileage intervals. Upon hearing mild clicks and/or pops, I was sure that the ASBL's needed replacing. Boy was I wrong. After the repair the clicks/pops continue.

I realize that the R model has a different suspension and probably more rubber bushings than I could count, so I'm looking for other owners of this specific year who have had to replace front end items to rid the car of sounds that are not normal. Tie rod ends, control arms, ball joints...all have rubber bushings that might be culprits, but I'm just guessing because I'm completely clueless about this model and it's possible front end issues.

I don't have any abnormal tire wear or steering issues, just pops when putting into reverse or drive. sometimes there is a slight (rat-a-tat-tat) when I'm stopped in traffic.

Thanks for reading.

Dan

One way to trace a noise is - chassis ears - look them up on google.

Perhaps you can find a shop that has a set - maybe you can borrow or rent them.

Take a good look at the upper engine mount.
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Keeping it running is better than buying new

Popping: I agree with Klaus. At 100k it is not unusual for the upper engine mount to be on its way out. My 93 850's upper engine mount wore out at around 100k. If the rubber is cracked then it is toast...

Rat-a-tat-tat type noises at idle don't sound like suspension. Have you checked your exhaust? May simply be a broken or damaged exhaust bracket or retainer.

Well, after much reading after posting this note, I've decided that a complete control arm kit will be my next repair. Since everything in the kit has rubber bushings (control arms, ball joints, anti-sway bar links and tie rod ends) it seems like the logical repair for a 2004 model. Also, there are many repair videos on youtube about the P2 chassis and front end repairs. The car only has 100,000 miles, but it's age is a clear indication of why the bushings are brittle.

My other question and how it relates to the repair is cost, and the manufacturers who produce non-Volvo OE replacement parts.

FCP Euro has a kit with all the items mentioned above for $374. Sounds like a decent price, but I'm unclear about Lemforder/Meyle parts.

Lemforder seems associated with MB and I've seen the Meyle brand on volvo sites as alternate choices for a better price. Are these parts just as good?

I'm curious why you think the control arm is making noise when you are stopped. Is there noticeable play in the bushings ? Feel free to use a pry bar to move them (within reason). Our '04 V70 has 220,000 miles and the control arm bushings show very little wear.


Greg