I hope I am not getting in over my head on this one. Its time to replace most of the bushings on my 91' 240 wagon. The rear end is clunking and the front end wont hold alignment anymore. (way way past time to replace these bushings imo)

Any help would be greatly appreciated. I am looking at assembling a kit from IPD of aftermarket rubber bushings because they are so so so much cheaper. I like poly best but I'm not driving this car like its form the fast and the furious. is it really worth 2-3 times the price?

as for the trailing arm, I found this: Homebrew Volvo Trailing Arm Bushing Tool

I am also taking a look at a cheap press for the remaining bushings. Do you guys think a 1Ton press will suffice or will a 6Ton press be needed?

1 Ton Arbor Press & Other Arbor Presses - Harbor Freight Tools

6 Ton A-Frame Bench Shop Press

Also I really want to find some sort of "Master Set" of bushings but so far my search has yielded no results

 

I would avoid any aftermarket rubber bushings. Stick with OEM if you are going with rubber unless you want to be doing the job again in a few years. I believe you can still get all of them through online dealers. If you go poly, do your research as not all poly bushings last as well as others.

 

+1 on acts post.

$20 more for 6 times the force? Go big or go home (or back to the store) on the press

 

I personally don't see the point of the majority of poly bushings for street-driven cars. They will squeak if not lubricated consistently, and will destroy your ride comfort when placed in most areas of your suspension. The only exception I would say is with sway bar bushings...Poly bushings give you a noticeable improvement with little to no downside of harshness.


I've been down this road before, and decided to stick with OEM-equivalent rubber bushings (Lemfoerder) after trying Poly bushings for a few years.

 

I did the entire front and back Poly bushing replacement and the anti-sway bar kit from ipd, overload springs on my 90 240. When I was done, the car was completely a different ride. It's now has a much more ''sporty'' steering response, will take sharper turns. I really enjoy it but if you want to preserve it's 'fluffy' ridding experience you better stick with OEM parts.

 

So I got new ball joints, rubber bushings and Poly for the trailing rod. I got some sway bars off of a turbo sedan (21mm rear and 23mm front) and I am making some chassis braces out of steel tubing (the GT braces and lower braces)

this is going to be a ton of work but I will let you know the results. The only issue I have had so far is finding new sway bar D bushings for the 23mm sway bar. the diner car I pulled it from was in rough shape.

 

you might check with these guys, they probably have 21/23mm swaybar bushies...
SuperPro Suspension Parts | Poly Bushings | Suspension Bushes | Sway Bar Bushing Kits | Biggest range of polyurethane suspension parts, bushings and bushes including swaybar and sway bar kits manufactured in Australia. - SuperPro

ps. they are hands down the best poly bushings around by multiple accounts.

 

What is your guys take on attaching the rear sway bar via bushings to the axel as well as its normal position as bolted to the sway arms? Just like the IPD sway bars? is it worth the effort? I found 23mm bushings and they would have some to fit the rear as well pretty cheap.