Hi Folks,
thanks for previous advice on the strut insert spacers. If I had read a little more and seen daveshan site I would not have removed the strut from the car per the Haynes manual. Oh well - side two will be easier. I noticed some play (side to side)between the strut mount inner race and the strut rod. I get the same amount of play on both the old and new strut. Can the inner race of the upper strut mount wear that much? The bearings are fine and not separated from the rubber. I think the fit should be much better than it is but maybe this is normal and I am overly concerned. could this be the source of the rattle noise in the front end over rough road surface? If I need to replace the mounts should I go with the OE or the much cheaper aftermarkets. There is 157k on the car and if the piston slap doesn't drive me nuts I may keep the car for awhile.

I offer this having no clue about the history of your car, ie previous ownership, previous repairs, etc. I have experienced another source of the noise you describe. I discovered that on one strut, the gland nut that threads onto the top of the strut tube, had worked its way "loose". This allowed the insert to rattle inside the tube. This noise was most prominent driving slowly over a gravel drive. This rattle was less likely to be detected on usual hard road surfaces. Once tightened, bringing the flange of the glandnut to within 1/32" of the tube's top, that rattle disappeared.

Mike
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'83 245 GLT, '90 760 GLT

There is normally some slop between the strut shaft and the inner bearing race. Once the nut is tightened up to spec, all slop should be gone.

jorrell
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92 245 250K miles, IPD'd to the hilt, 06 XC70, 00 Eclipse custom Turbo setup...currently taking names and kicking reputations!

At 157k, I would be highly surprised if the original strut mounts are worn out. IMO, they last well into 200-300k. I would not replace them unless you really think they're bad. Do not use the cheap aftermarket ones. They do not last.

A worn or broken strut mount will make an obvious metallic knocking sound during suspension movement or low-speed turns.

Rattles from front end are usually due to worn control arm bushings, and/or worn sway bar bushings.

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'92 240 wagon, 285k, '90 240 sedan 229k

Just a data point - on my '92 245, both of my strut mount bearings were shot and groaning by 150K miles. YMMV.
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In God We Trust. Everyone else, keep your hands where I can see them.