My Bilstein TCs got clunky on the 940 after a few months, especially on parking lots with lumpy patches. One leaked within a few weeks too. FCP that one right away, then both later (with Boge if I remember right). Problem solved.

IMO, the noise is internal, and not related to mount bolt diameter.
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Bruce Young
'93 940-NA (current) — 240s (one V8) — 140s — 122s — since '63.

Bilstein replaced mine due to the diameter of the shock mounts beung too large for the stock bolts. The 2nd set has the same problem, and Bilstein has so far done nothing except tell me that the bolts are not OEM sized. RIGHT!

So I picked up a set of ProGas (yellow) Bilsteins that fit and will swap them and sell the TC's on Ebay.

TC's are not made at same plant as ProGas Bilsteins, QC/QA is non existant IMHO.

My Bilstein HDs were clunking in the rear. After months and $$ spent replacing bushings, etc. finally swapped sides and the clunking also switched sides. I sent them out to Bilstein and one was indeed deemed faulty. They replaced both the rears (even though only one was busted) no questions asked with brand new ones. I'd send them back!

Best,
Adam
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'92 244GL silver-metallic, 150k, Enem V15 cam, Bilstein HDs, IPD sways, upper+lower braces, Cherry-Turbo strut brace, 240 OEM rear spoiler, 15' Dracos, E-codes w/side repeaters, Euro cowl covers paint-matched, Magnaflow 2.5' SS exhaust w/Unitek header

Are you sure its the shocks and not the panhard rod bushing? or maybe the rear trailing arm bushings?? Sounds a lot like trailing arms to me..But then again its late and I do not think at this time of day..":)
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Max..1989 244 DL 5 Spd., Bilstein HD, Turbo Swaybars, Poly Bushings all round, Turbo Wheels, Black leather interior, Electric mirrors, LED dash and gauge lights.