DIY: Front Suspension Rebuild (2005 XC90 2.5T AWD with 120K) Topic is solved

[erikv11]

Easiest way to separate the control arm is while it is in the car. I prefer using a cheap S-hook with pry bar, but a 2 lb. hammer alone works.

For removing ball joints from the knuckle: You will see posts that say "just whack it with a chisel and hammer" but that may not work if it's really stuck.

For corroded old P2 cars I've done it 5 times now using an air hammer with a pointy bit. Ball joint came out fairly easily. But also had one very stubborn one (the 6th!) I could not get off that way. For that one I ended up taking the knuckle to a machine shop and they got me out of trouble.

[xHeart]

Heat and hammer combo worked; thank you!

[xHeart]

Success, thank you all!
Torque for new fasteners simplified.
- 130Nm for screws with 18mm hex heads, cross nut, and 21mm nuts
- 80Nm for screws with 15mm hex heads, and 18mm nuts
- 50Nm for screws with 14mm hex heads, and nuts

FWIW: compress spring to 260mm for easy and safe strut disassembly and assembly.