2003 S60 2.4t
Shopped and found for what most looked like the mount in picture on website.
I received a part that was miss labeled on the website. Apparently they sent me a lower coil spring rubber cone.
My strut mount top cap has worn through so the strut pokes the top when I push down on the front passenger side.
I see other strut mounts on line but they don't have a cap. Do I need a new strut mount and how many pieces are there?
Little help please and thank you.
And I thought this was going to be easy LOL

 

I've clipped a picture of how the strut parts work. Reassembling the strut from bottom to top goes like bellows/bump stop/bump stop washer slide on first. The spring goes on over that and the rubber spring seat fits on top of the spring (which should be compressed to about 11 inches). Line up the spring to the slot on the strut, then line up the spring seat's spring end slot. The strut mount/bearing slips onto the spring seat (the rubber is grooved). That is all held down by the "cross nut" which goes blades up, torqued to about 50-55 ft/lb. The top strut washer then goes over the top of the strut bearing (I think its flat side down/ridgy side up but I need to look...). The top nut then goes over that, again torqued to about 50-55 ft/lb. If your top of the strut rod/with top nut is wobbly, its most likely the spring seat is torn between the rubber and the metal sleeve that slides over the rod. I suppose the strut bearing could break as well. Check out part numbers 30683637 for the seat and 30714968 for the bearing. The top washer is 30647969 but you'd see if that was broken.

 

There is a steel sleeve embedded in that rubber mount (#7), and the sleeve is firmly bolted on the end of the strut. When that rubber mount goes bad, the sleeve escapes from being fixed in the rubber. Then, the top end of the strut starts clunking up and down during suspension movement. It sounds like to me that is your problem, but it's hard to be clear.

 

When replacing your upper spring seats, don't go with original S60 replacements. Go with either the heavy duty upgraded version from iPd or the stock version made for XC's.
They are both thicker and stronger than the stock S60 version... which reportedly only last a few years.

 

Thank you mt6127 and firebird.
That #7 part was exactly what I bought. I found that out by taking it to Volvo of SM and the mechanic confirmed it was correct. Found a shop near by that put it in for $60. Double score! I had estimates from other shops for around $300 part and labor.