Hi All,

A clunk quickly developed on the right front side of the volvo after I changed the strut insert. Initially it was not much prominent but now it thrives and even takes over the conversation in the car. There is a metal clunking audible at low speed, while driving over bumps (both going straight and also when turning). Seems to happen when the suspension is unloading(?). The clunk can not be heard when driving at highway speed.
I thought the strut was installed incorrectly and opened it again, just to put it back the way it was. Could it be something else?
I have read whatever I could on the topic. One notable reason for the clunk seem to be the strut top nut not being tightened enough. Another one is a missing spacer inside the strut which seem to be relevant to 240s only.
I want to open it again and get it fixed. Please share your wisdom on how to get that done properly.
The left side creaks and pops when turning the wheel so I am hoping that the bearings are shot there..

Delforza,

Glad you got it worked out, I couldn't tell from the photo, probably would have looked in manual. Either way, yous seem good to go. Maybe needs an alignment now?

Yes indeed! Good point. The car pulls heavily to the right.
First the left strut still needs to be fixed (maybe next weekend) - it creaks and there is a popping sound when turning the wheel. Hopefully will be able to fix it following the same steps but opening the yellow disc and checking the bearings..
Oh, I worked on a number of things on the volvo and many of them were fun. Compressing a spring for 3 hours is really not.
I will try to post better pictues of the parts found in the left mount..

Thanks you all for the helpful suggestions!
Is there any diagram on how the parts go together. There are a number of washers, plastic spacers etc that could fit in a number of different configurations.

Best I think to shoot some pics of what you have; discussion would be much easier/clearer.

I at first thought the job was done by a shop; maybe that's inaccurate, in which case, we all make mistakes. But it must be fixed or damage will ensue.

Yes, I messed up big time on this no question about it :)
Attached is an image with the parts in the respective order they were.
Are parts missing? The third part counting from the left (a big curved washer) seems out of place because it is sort of freely moving around when sandwiched b/n 2 and 4 from the left. 5 is also freely moving b/n 4 and 6.
Many thanks for your help!

The third part from the left in the pic I see, is the smallest part of them all.
It sits on a shoulder on the strut rod (approx 3-4" down from the threads) on its inner surface, and is mounted under the 2nd part from the left, the upper strut mount, where there is a recess for it and on some, some small fingers that sort of hold it in place up inside the strut mount. It is vital. It does not 'freely move around' when all the parts are assembled.

The 4th part is a shaped metal plate that's sorta like a frisbee. The bearing which is the yellow part, sits on top of it, and under the upper strut mount. Actually it's better to think of it as the bearing sitting under the strut mount, as there's a spot in the rubber for it.
Edit; the yellow part; do you have a better/angled pic of that? I think this may be the problem.

The rubber spring seat of course goes under the metal 'frisbee'.
The round thing between the metal plate and the rubber spring seat, I'm not sure; it sorta looks like an internal part of the bearing...
Um, the yellow disc on the frisbee plate; did you take that apart? I think what I'm seeing is the bearing disassembled, with no actual balls inside.

oh, the "yellow disc on the frisbee plate" was not taken out in the picture. The "yellow disk" and the "frisbee plate" indeed can be separated! Also the yellow disk can be opened and there are bearings inside and they are greased and rotate freely. I am also not sure about part 5. It is a plastic ring that was inside the groove of the "rubber spring seat".
I had to start putting it back together and just finished. Thank you for walking me through this.
It drives great and there is no noise at all!!!
Thank you jerryc and Milanomike!

No pic.
I use imageshack, which is free and simple, others use photobucket, and there are others.

great! here is the picture:
http://img9.imageshack.us/img9/2351/6fiv.jpg

Milanomike: I tried threading the cap in as it stood but could not; thanks for the tip! Anyway, it is a good opportunity to check for missing parts..

Delforza,

You may be able to lift the dust boot and use a drift to tap the cap nut around. Of course, assumes it's not cross threaded or some other irritating issue with it. If that won't work with a couple of love taps, I'd take it back out, compress the spring and fix it. Put some anti-seize on it while your there. Good luck.

You didn't mention what strut insert you put in, I'll assume a standard Sachs for the moment. I just did this on my 93 a few months back. You need to make sure the strut cap that holds the insert in the strut tube is on snug (tap it with a drift), then make sure insert is snug in there, i.e. can't move up and down, it shouldn't, but you never know. Inserts come with new strut caps. Is the spring correctly seated, i.e. ends of spring located in upper/lower perch correctly? Everything back in correct order and top nut snugged down? Otherwise, assuming good strut, that is all I can think of.

Straight to the point Milanomike! Yes these are the standard Sachs.
The "strut cap that holds the insert in the strut tube" (it is metal with threads) is not screwed in at all! May this be making the noise?
Do you know if it can be screwed back in now or the strut has to be taken apart?
Thank you!

What? the cap is not screwed in? Unbelieveable. Take it back quickly. Well not 'quickly', don't drive the car much til it's done.
And hearing this, have them completely take it all apart and ENSURE the heavy washer is in place inside the mount, that sits on the strut shaft. If it's not there, the strut will make a hole in the hood. Which is bad.