Two 1995 940s: I installed IPD urethane control rod bushings in each. And both now suffer from suspension clunks over bumps and potholes. Anybody experience this? Cures?
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See the 700/900 FAQ at the select shortcut button on the top right of the screen.

I have the poly cone bushings in four of five of our 700/900 cars. Firmer, yes. My car gives a few squeaks from them, but no clunks or bumps.

Did you do any other suspension work, maybe front strut cartridges?
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john

No clue. I did replace the strut mounts at the same time after being frustrated with some bumping in front. But this is new. The Boge Pro Gas shocks seem to fit poorly in the tubes compared with the Bilstein HDs. I hope I got the top washer back in the right position: I installed it with the concave surface down.
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See the 700/900 FAQ at the select shortcut button on the top right of the screen.

I know I used to use the Bisteins. Why did you switch to the Boge Turbo gas charged strut cartridges?

I suspect your clunking sound is the strut cartridge tube moving slightly up and down inside the strut. Jack the front end up and try tightening the nut on the top of the strut tube. I have experience with this, having experienced the clunk also. It was just a slight looseness of the nut on the tube.
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john

I actually had to drop a couple of fat washers into one of my strut tubes to shim up the insert to stop the clunk.
Yellow Bils, too.

Bistein offered strut cartridges the 240 prior to offering them for the 700 series. IPD discovered the 240 strut cartridges worked in the 700 MacPherson struts with about three steel washers in the bottom. IPD sold the 240 strut cartridges to 700 series owners with the washers until Bilstein came out with the cartridges for the 700 series.

I have a set of Bilstein 240 strut cartridges which cam out of the 740, with three washers in the bottom of the strut tube.
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john

This already happened once on the passenger side strut, so I'll have at it when it warms up today and see if I can fix it. The last fix was simple: just tightening the gland nut.
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See the 700/900 FAQ at the select shortcut button on the top right of the screen.

Problem solved. I disassemble the left front to find that the new strut mount had in integral washer mounted inside. In the cold at night, I merely replaced the old washer, doubling everything up. Once it was removed, the problem was eliminated.
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See the 700/900 FAQ at the select shortcut button on the top right of the screen.

First, check that the bolts are torqued to spec. I found that poly bushings were too harsh for my taste, and switched back to standard ones. They are especially harsh in the cold weather - people would look a bit scared when I hit a bump.