As much as I hate this particular job, it's that time again. Both of my 240s ('91 245, '93 244) need strut mounts, strut inserts, and rear shocks. I've followed many of the threads on this subject, so am aware of issues such as universally crappy OEM-style strut mounts, Sachs/Boge struts/shocks made in Mexico, noise/mounting problems with Bilstein Touring shocks (rear), and problems fitting Bilstein HD inserts in ABS/'90-> strut tubes. FWIW, I've used Bilstein HDs on a couple of 240s in the past and liked them a lot, but understand that the front strut inserts are a no-go on the ABS-equipped sedan at least. All in all, it seems that my options for a repairing our trusty 240s have narrowed to the following:

1) use Volvo OEM inserts and shocks (but I have no experience with the OEM replacements lately--are they decent or have they gone Geely?)

2) use Bilstein Touring Class strut inserts in front, with something else (Bil-HDs maybe?) at the rear--but I'm reluctant to mix front struts and rear shocks.

3) install Koni yellows front and rear (I've used Konis on other cars in the past, but not on the 240--anyone able to share their experiences? How was the install? Ride, handling, NVH?)

Regarding the strut mounts, I've already picked up a pair of BNE spherical mounts from Kaplhenke Racing--if they work on the wagon, then I'll get another pair for the sedan.

FWIW, both cars are daily drivers, though we also use them for extended road trips, mountain driving, etc., so I'm looking for good control without excessive harshness...

That's it for now, but any advice, BTDTs, other wisdom would be GREATLY appreciated. I'm sure I'll have additional questions as I get into this (for example, which inserts require removing the spacers at the bottom of the tube, etc, etc), but I figured I should start small...

THANKS in advance!

Steve A-

Yellow Koni Sports and Ben’s spherical luxe steer bearings in mine. Wouldn’t make any other choice.
--
82 242-6.2L; '17 Mazda3; '16 Crosstrek

Hi Michael,

Thanks for the quick response! I have the luxe steer pieces too.

Where did you buy your Konis? Any hints on the install? Did you need to remove the spacer at the bottom of the strut tube? Do the inserts come with a dust boot? Any/all tips on the installation and set-up would be appreciated.

Thanks again (and be careful in the NC snow!)

Steve A-

BTW, sold the old V8 wagon last spring--23 years after the initial conversion. I hated to see it go, but it went to a good home.

Koni yellows are a good choice. I use them for front and rears on one 240 and just the rears with Bilstein HD's in the front on another. Check Tirerack for a 20% off sale.

When using the Koni yellows on the front did you remove the Volvo bumpstop and protective sleeve? Did the Konis come with a protective bellows? Any other BTDTs?

THANKS!

Steve A-

Search online Steve for Koni’s tech line in Kentucky. An engineer named Mason O’hara was very helpful answering questions for me. I don’t think it matters much what we remember about how ours were or weren’t equipped in the past; what matters is what will you get if you order them today. Info below from years back when I did mine.

mason.ohara@itt.com Koni a part of ITT Motion Technologies then; not sure if they've been bought/sold again since.
--
82 242-6.2L; '17 Mazda3; '16 Crosstrek

Thanks Michael, I'll call him after the holidays.

Steve A-

Say no to Bilstein H6 HD.

Bilstein HD has a nasty issue with water getting inside the strut cartridge. In cold weather, the water freezes and the HD strut seizes. The struts can break internally. The issue effect all Bilstein HD across all makes they fit such as BMW, VW, and other forums.

Bilstein Touring rear rattles on the top and bottom mounting studs. Front struts are great.

No more real Boge shocks. All made in Mexico Sachs and I regret buy these from iPd.

Koni and Kaplhenke for strut mount. The Volvo OEM 1272455 is Chinesium garbage. No OEM style struty mounts seem to exist anymore. The good ones have roller ball bearings. All the cheap one have a sealed bearing race that rails rather quickly.

https://forums.tbforums.com/showthread.php?t=315522

Get the Volvo 240 Turbo strut piston bellows with the hanging 'washer' the bellows hang on at the top. These bellows were used with the Volvo 240 Turbo setup with the orange De Carbon strut cartridges (like Bilstein HD).
--
Give your brickboard.com a big thumbs up! Way up! - Roger Ebert.

Thanks for the info on the HDs trapping water--hadn't heard that before. Also, I appreciate the tip on using the bellows and washer from the turbo. I'm assuming you're talking about Volvo PNs 1272624 (bellows) and 1272623 (washer). I'll talk to my parts guy and see if they're available.

Thanks again,

Steve A-

Hi Steve,

The protecting bellows and the washer - hanger thingy are both available.

Bellows Diagram #5
https://www.tascaparts.com/oem-parts/volvo-stopper-1272624

Washer Diagram #6
https://www.tascaparts.com/oem-parts/volvo-washer-1272623

A Diagram here:

https://www.volvopartswebstore.com/showAssembly.aspx?ukey_assembly=234339

Tasca is probably cheapest with maybe a shipping fee.

What sucks is Volvo strut mount OEM 1272455 is such garbage.

Though no one relates the camber plate ride. Kaplehenke seemed to suggest maybe three-five years for the spherical bearing to show wear in a daily driver, requiring strut assembly removal for camber replacement.

Waggon Meister or someone, and I forget now, made mention of making PN 1272455 strut mounts using urethane for bushing material and a quality roller bearing assembly as was originally in 1272455.

I got three sets of two strut of the last OEM mounts and under the dust cap is some SuperLube synthetic silicon grease.

Hope that helps.

Diagram:

--
Give your brickboard.com a big thumbs up! Way up! - Roger Ebert.

Thanks, this is a big help!

Been a while since the install....

Yes, I seem to recall they did come with dust boots. Had to order external bump stops though. Cut up one of my box end metric wrenches to make a "spanner" to tighten the top nut. Mine's an 82 -- don't remember any issues with the spacer.

Ha - I don't drive in the snow unless I absolutely have to. I freakin hate snow.

Thanks again!

Steve A-