Alignment Problem On 2004 Volvo S60 2.5 T

[Memuns]

It began with me changing the lower control arms, ball joints, front struts, front sway bars, rear sway bars and rear struts. All at the same period on my 2004 Volvo S60 2.5 T. I used Karlyn control arms and Karlyn ball joints, and used Meyle struts and sway bars. All parts were purchased from FCP Euro. After weeks of painfully changing all the parts including changing the axels, I decided to take the car for alignment. The technicians at the alignment shop told me that they couldn’t align my car because the toe on the front passenger side is way out and they couldn’t bring it in, they said the inner tie rod will not spin further to bring the toe in. They then suggested that I change my inner tie rod and bring it back for alignment. I took my car home and order a new TRW inner tie rod to replace the existing one and half year old Meyle tie rod on the car.
After the replacement I took the car back for alignment, same problem as before, cannot do the alignment because toe on the front right is way out. I took the car to another shop, same problem, the car will not align. Now I don’t know what to do. I cannot drive the car. Any help is appreciated.

[oragex]

Maybe the steering wheel was previously removed and replaced off center? I don't know if this can be done on Volvo, I remember having this issue on a Honda.

[cn90]

Couple things:

1. The "straightness" of the cabin steering wheel has nothing to do with the proper alignment of the tires.
However, the SW should be in the neutral position when the tires are pointed forward in perfect alignment.

So, you need to clarify that the tires are straight regardless of the SW position. Once you establish that, remove the SW and re-position it.

2. I usually don't mix and match (such as TRW with Meyele), but this is a minor point I am trying to make.
I use only Lemforder, TRW or Volvo parts all around.

[vtl]

I've had similar problem with TRW tie rod end: one just haven't had enough thread in it. Managed to cut 10 mm of tie rod (Lemforder), that did it. Other side was ok.

This is exactly why aftermarket parts are cheaper (inferior quality).