I replaced the front struts on my 2003 s6 AWD T2.5 a few months back only to have the upper rubber mount fail. I'm trying to figure out if I did something wrong or if the items just failed. They failed on both sides. Does anyone have a good diagrame (IPC) of the fron strut and associated piece?

 

I see you have another thread, yes, they fail often. Someone may be able to get you a diagram., but it is where the spring meets at the top, the black piece.

 

Originally I used the strut replacement guide at member.shaw.com. It was very helpful and I didn't have any problems or complications. Every thing was fine for a few hunderend miles. I did notice a 1/4" gap after a few hundered miles under the hood between the seat and top "plate" (sorry no IPC to get exact names of pieces). We aircraft mechs rely on IPC. I've struggled without a good manual.
After a few thousand miles my wife told me she was hearing a hard thud,clunck whatever over bumps. I looked under the hood and noticed the strut has pushed thru the "black piece the spring rests against". I believe it's called the spring seat.
The strut still has 3/8" of the spring seat attached to it and the rest is separated.
I find it odd that both sides failed. I need to go back and look for reciepts because I can't remember if I replaced the seats when I replaced the struts. I thought I had but I'm getting older and I can't always remember what I'M doing from day to day I guess I could understand if the seats were not replaced. The new stronger struts could have made the seat fail.


I have the struts back out and new OEM seats. I just want to make sure It is not "mechanic error" here. The IPC would be helpful to make sure I have everything back together properly without anything missing.

I ordered a Hayes manual yesterday (britsh model) and hope this will tell me more.

If I find a good diagram of the unit I'll find a legal way to reproduce it and post it to the sight for future "strut woes".

 

I can get you one today, although it may have to be faxed.

 

Well the Hayes manual just showed up and it would appear that I installed everything correctly. There is no IPC (diagram)but very good step by step directions and pictures. There is one part I see that was not on my original struts(?) or I lost. It is the bump stop that sits under the seat between the strut and seat. Are these something that I'm missing??

 

You do not have to have it I suppose, it keep debris out, so longer life.

 

Well that would make sense. I do not believe it was there on the original struts. I did get the local Volvo dealer to send me an IPC (i was amazed). I tried to order the bump stop. First they told me there wasn't one, then they sent the IPC and it showed one, Now I need to get the chassis number to order.
This is all a bit confusing for my small and feeble brain.

 

In case any needs a good diagram of the front strut of an S60. Here it is.
Kind of new to this forum but I've tried to attach a jpg of the diagram.

 

Do you have to take apart the brakes to replace those spring seats, or can you just take the bolts attaching it to the brakes off?

 

Just the strut bolts on the steering knuckle and the sensor for ABS.

 

I had the exact same issue. I replaced the front struts only but not the spring seat nor the strut mount. I few hundred miles later I noticed noises when I go over bumps. I opened up the hood and sure enough the spring seat was not doing its job. I'm about to replace the spring seat and mount but was wondering if I should purchase the bump stops?? Any idea if those go bad too?