Rear springs.

We've had 4 240's; every one of them needed new rear springs by the time they had achieved as many miles as yours has. Sooner, in fact.

You won't need a compressor to replace the rear springs.
Need a 1/2" drive breaker bar.
It's several additional steps beyond changing shocks, but with everything else you're doing in the rear, you'll nearly have the old springs out anyway.


fcpgroton.com has standard and "heavy duty" springs.
Moog makes "overload" replacement coil springs, currently in use on my daily ride as replacements for the stock item.

Your new sway bar bushings will probably require the new style brackets. Those things are a pain but are nice once you finally get them together. I think I would have had an easier time with some longer bolts for them.

I'd concentrate on fronts first, and replace the ball joints, outer tie rod ends, and upper strut mount/bearings. The inners are likely to be worn out too. There are some suspension kits, i.e. bearings, outers, ball joints, from suppliers for a good price. The inners are always separate and more expensive.

You'll have trouble getting apart the upper strut mounting nut unless you have an impact wrench. A shop may bust those loose for you, then put it back on so you can drive home and remove it yourself. The big nut holding the strut cartridge into the strut tube will be fun as well. A big pipe wrench or two will help. You'll need spring compressors to take this apart- be very careful, there is a LOT of energy in a compressed spring.

Good luck with it!
--
Rob Bareiss, New London CT ::: Roterande Fläkt Och Drivremmar!

I would split the job for front and rear. I'll add a few things but I'll probably miss something to. I think repainting everything with POR 15 is also worthwhile.

Front.
strut mount/bearings
repack wheel bearings or replace
brake hoses
rebuild calipers
tie rods,ball joints,check inners
splash pan

Rear.
panhard bushings
brake hoses
emergency brake shoes
wheel bearings
rebuild calipers

Don't forget the strut mounts. Since you are going to be taking that assembly off anyway, might as well replace them. Also keep an eye out for rust on the strut assembly area. And it wouldn't hurt if you replaced the bushigs for the sway bar end links.

--Joe HC
--
1977 244 160k (?), 1990 244 102k, 1978 Fiat 124 Spyder (restoring)