1-5-3-6-2-4

Need clarification. Did you install V70 awd struts or V70 XC awd struts? I pulled up some sites looking to see if there are any differences. I don't see a separate strut for the V70 fwd vs awd (or for a spring), but the control arm has a different part. Although for the XC variant things are differe...

~1" higher with new quick struts (new coils included) is normal if indeed you used AWD parts rather than the XC70 parts.

Her S60 sat much higher for about a week or so until everything settled. It's still higher than before though.

Look up the label part numbers on the old and new units and compare fitment.

It could be the rack itself. Remove the rubber boot and try to wiggle the coupler below the U-joint. That was the end of my steering rack: https://www.youtube.com/watch?v=JTrfZYCQbEk As for the coupler, you can try to smack it off from beneath (the car should be on the ramps) using a long 1/2" ...

As above, too much - or perhaps even little forcing may damage the rack box shaft seal. Even the penetrating oil that you sprayed on will usually leak on the top of this seal and can damage it. Try to cut off without damaging the rack shaft

after removing the pinch bolt try inserting a screwdriver blade and prying the slot open a bit to break the bond to the shaft.
Also try inserting the pinch bolt backward, block the slot with a knife blade, the pinch bolt should push the slot wider.

After decade+ of permanent heat/cool/salt/water the aluminum and steel weld into each other. I was removing it forcibly with a small sledge hammer (5 lbs or so), it was tough. In my case it was fine to destroy the rack (which I did), because I had a factory rebuilt Bosch-ZF laying nearby. Also the s...

I sweated the same problem on the T5 and had to remove the rack to get that coupler off. It really rusts on. Chance of damaging the rack is really high with chisels and other 'methods'

With luck maybe some wires/connectors just got pulled out behind the airbag. Find a video on replacing the steering angle sensor, it'll show you the lay of the land behind the airbag including the connectors for those controls and horn that are oriented such that they could well have been pulled out...