Help!!!! Rear Strut Rebuild Issues-2000, S40

Post by **uhlan** » 21 Apr 2012, 23:23

I am in a rather serious predicament here. Hope someone can help.

Have removed both rear strut assemblies, and successfully taken the coils/springs off. Problem now is getting it back together. Issue is that when assembled, I can’t compress the rubber washer that sits on top of the top strut enough to thread the bolt onto the tip of the strut. I have uploaded a black and white image from my manual which shows what nut I am talking about. Also have images showing some of the reassembly of the strut.

What is the trick to getting to compressing that washer and getting enough thread visible to get the nut back on?

Did I reassemble something wrong on in the top of the strut beneath the strut mount?

Anyone have a good diagram of how the components go back on the strut, beneath the upper strut mount?

Do I have the long bushing in the wrong place? It goes inside of the dust cover, I think because I see a ring mark on the inside top of the dust cover, which is very similar to the diameter of the bushing.

Any help would be appreciated.
Many thanks.

Post by **MoVolvos** » 22 Apr 2012, 00:39

Are you using spring compressors?

Blessings,
BKM
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Post by **uhlan** » 22 Apr 2012, 01:19

Yes. Springs are compressed and not in the way at all at this point. Even if I try to thread the nut onto threads without the spring on the strut, I still don't get enough thread showing through the rubber washer/groument to be able to even hand thread the nut on to get it started.
I think I must be reassembling some hardware component on the shaft incorrectly.
BTW - Thanks for the reply. I appreciate it.

Post by **MoVolvos** » 22 Apr 2012, 17:25

Here are some diagrams that may help you to remember how it came apart

http://www.swedishautoparts.com/S40/Vol ... -rear.html

http://www.rockauto.com/catalog/raframe ... 05-2606560

http://www.partsgeek.com/gbproducts/DC/ ... nt+Bushing

I tried enlarging the picture below and am wondering if the V Cone shaped rubber bushing is not a correct part comparing it with the KYB Kit and other pictures and diagrams? Your last resort is to go to Volvo and have them print you or show all the parts. One last note is the boot properly attached to the rubber grommet below it?
http://www.ebay.com/itm/Volvo-S40-V40-R ... 2ebd66972f

Blessings,
BKM
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