I've had issues with my steering for almost as long as I've owned my 2004 S80 T6. The symptoms are many and I'll start with some history. The entire front suspension has been replaced within the past 2,000 miles, and car currently at 200,000. New bilstein front shocks, ipd HD strut mounts, new strut bearings, new control arms, new inner and outter tie rods, new HD ball joints. Upgraded new ipd front and rear sway bars with new sway bar bushings, new ipd hd sway bar links also. During this time I also replaced my steering rack with a remanufactured detroit axle steering rack and brand new ujoint. Mine seemed to have developed a "pop" in it noticeable during parking lot manuvers and it feels loose during straight line driving, especially below 50mph. After the remanufactured rack and all new suspension parts were installed, I still have that same "pop" from inside the rack and looseness happening. I've adjusted the yoke on both racks and this does seem to help the symptoms some but are these racks known to fail? I've looked into buying a new updated "2005" rack from volvo but that looks to be ≈$1400 plus a new steering u joint to steering column to make it fit. Anyone done this or had any experience with these issues before I drop a couple thousand?
I have had the suspension looked at by a volvo specialist with "everything looking good and tight" and I've had the car up on a lift and inspected the suspension numerous times with no play but can clearly hear the sound in the rack when someone is turning back and forth and I'm under hearing and feeling it where the steering column ujoint goes into the rack. Any ideas? Anyone? thanks! - Luke