This is an excellent site with great info and hopefully my first post can also help someone out.
My 1999 S80 is sufferring from a front end clunking noise. The noise is most prominent at low speeds (20-30mph) while on the brakes and turning sharply, for instance at an intersection. Since I live in the city and have quite a few of those to navigate daily the noise has been wearing thin on me!
I am a fairly experienced wrencher and between my father and I a few Volvos have graced the garage and all of them have had clunking noises at one time or another. I've gotten pretty good at diagnosing these unfortunately and have already inspected the Control arm bushings, ball joints, sway bar endlinks, tie rod ends, spring isolators and upper spring mounts -- they were all in excellent shape. I was a bit confused at this point.
I drove the car some more and could feel the clunk in driver floor just under the brake pedal and now I am 99% sure it is the rear subframe bushings. While the car is turning and braking the chassis of the car is shifting a bit forward on the bushing while the subframe is staying put which is resulting in the clunking noise.
I then found this site and some good information in the following thread:http://www.matthewsvolvosite.com/chat/phpBB2/viewtopic.php?t=5819
After reading the thread I am sure that the O-Ring kit for the bushings is exactly what I need so I went to my dealer to order it and the parts guy looked at me like I was crazy. So I went back home and looked it up in Vadis. Found it in 2 minutes! It is RIGHT there listed as a TSB under Engine (in this section since the subframe is the engine's mounting point to the car).
Basically as the thread above also states these large "o-rings" take up any slack in the bushing and keep it from shifting in the subframe. You will need two o-rings and two new bolts. I will be ordering these from the dealer tomorrow and should have them in this weekend and will report back.
Here are the part numbers:
Description Quantity Part No.
O-ring 2 8638585
Screw 2 981062
I also created a pdf of the issue with part numbers and instructions from VADIS for anyone else who has this issue and they can take them straight to the dealer.Click HERE to download the PDF
For the record my 1999 has been quite reliable with the only major issue being the cylinder 6 injector getting stuck open resulting in huge white plumes of smoke coming from the tailpipe. The car looked like a rolling factory! This clunking noise is the second issue for me. I bought the car a year ago for my wife with 101k on the odo and paid $8000. I consider it a great value and since I can do all the maintenance myslef I can actually afford to KEEP it.
Omer F. Khan
1999 Volvo S80
1992 Nissan Sentra SE-R