Cracked front lower rear bushings can be replaced as follows:

Removal - jack front side to be changed & remove wheel, be sure to use jack stands for safety. Remove two lower ball joint bolts, bushing through bolt & front assembly bolt & nut. Loosen remaining three tie bar bolts to permit removal of lower control arm. Drive screw driver under bushing flange & ply to crack plastice flange away - this will permit exposure of bushed member for pressing out. Use #3 Pressing disk from SPX Volvo Tool #9995567 or make (this disk has 2.676" OD x 0.473" thick w/ 0.030 chamfers). I used a large vice & steel blocks to permit press-out.

Installation - scrape control arm bushing bore w/ knife followed by sandpaper & steel wool and apply a thin coat of Vasoline. Use metal oil filter wrench that fits Purolator L14459 (PER 4459) filter. This wrench Fits bushing flange nicely and transmits the force required for pressing home w/o cracking plastice flange. Installation of control arm is the opposite of removal above.

Ref. dimensions: Control arm bushing bore = 2.767" ID, Bushing Flange OD = 3.34", Bushing insertion OD = 2.833"

Time: approx. two hours per side

XKE
Thanks for the info about the front bushing replacement.
Every thing is very clear to me until I read the part of the oil filter wrench. I am guessing that I fit the filter wrench around the plastic flange and apply pressure, but how are you holding the bushing to be able to apply the pressure and fit it in the control arm at the same time. I may figure this out once I start the job, but I don't want to ran into trouble in the middle of the task. Can you please explain this process a bit more. Thanks

The inner front bushing bolt should only be retightened after the car has weight on the suspension. If not, you will leave a lot of strain in that bushing which will make it fail quickly, if it hasn't already.

I bought the Volvo press tools and used a small arbor press to do mine, bot front and rear. I also started with the front wheels on ramps so I would be able to retighten the front bushings with weight on the suspension.

New bushings took all of the loosness out of the suspension. Drives like new again.
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'96 965 with 16' wheels, 18 mm rear bar & 204 HP cams at 122K

Thanks for the details.

DEWFPO
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1998 S90 071,245 and 1995 964 154,100