Go to IPD at:
http://www.ipdusa.com/
for better aftermarket sway bars. I also installed the strut brace. No problems.

if it's any consolation ,i understand your frustration, having just gone through chasin this stuff myself..i finally (fingers crossed) got it right.this may or may not help .i've got a '98 v70t5m.i replaced struts/shox and all of the associated mounts .i even replaced a arm /ball joint on one side. still the clunking continued and now it was on drivers side as well.i replaced the sway bar links( which i was told were "young") that corrected the problem...but the point is one loose part begets another.check everthing they tell you to on these forums ,including rack ,a arm bushings and strut tower bolts etc. go thru every damn one....one at a time... and you will find the problem.sway bar end links are certainly expected to do a lot...and mcpherson strut setups are weird but persistence will prevail and so will you GOOD LUCK

I'm with 'ya on that one. I have a '99 V70 and experienced the same problem. Last spring, I had the sway bar links on the driver's side serviced under warranty. Last month, the noise returned - same side. I am bringing it in for service next week and will let you know what transpires.

I have had the same repetitive problem on a 2001 V70. Six times. The last fix seems to be holding. In addition to links, I was shown a bushing (I can't identify it beyond saying it is a horizontal barrel-shaped bushing behind each front wheel) that was horribly loose (could be shifted by inserting a screwdriver blade). The bushing looseness apparently contributed to short life of links. The links seem to be holding now that the bushing was also replaced. Also, I think I have seen references to a new stabilizer design that is more robust and can be afterfitted to our cars. (I'd love to see some confirmation of this) That will be my line of inquiry when the problem next occurs. You want to keep on top of this since premature tire wear can result, which will be your expense. As frustrating as this problem has been for me, I have to say I just returned from a 1000 mile road trip in wonter conditions on which the car performed superbly and was a joy. Some consolation I hope. Best wishes.

Pretty unfortunate that you've had the front sway bars replaced 3 times already. Something else may be bad putting a strain on the bars (strut towers, etc - see previous person's post). If not, you may bite the bullet and replace with larger, better constructed after-the-market sway bars (IPD has good ones). You can possibly get Volvo to throw in the labor to replace if you buy the bars.

Have you/dealer checked the strut mounts? If it's not the ball joints, sway bar links...there's not much left but the strut mounts. Maybe the steering rack is not bolted down tight...seen that too.