I have the usual set up for sway bars on my 245Ti. IPD 1"ers front and rear.

I have all new suspension components, new bushings, new rack, every reinforcing/shock tower bar purchaseable. All fasteners are properly torqued. My front suspension is very solid.

Still a problem remains. A click/clunk on the right side when going slow/turning.

At first I thought it was the strut loose in strut tube again. Being a 240 turbo the car has the longer gas strut tubes. I put KYB's in with the Volvo spacer AND a stainless steel washer. There just can't be much room for the stut cartridge to move up and down. I have tightened the heck out of the center nut with big pipe wrench. But the noise didn't diminish as I cinched the nut down. The big nut does appear to be bottomed against the top surface of the strut tube, which may mean it hit there first before locking against top of the cartridge.

So here's where the story gets weird. John Laughlin drops by yesterday to check the electric fan out. We are chating Volvo and I say: "Hey John, bounce my beast". (John's a big fella). So here I am under the car with my automotive stethoscope listening to all the moving parts while John is sweatingly bouncing.

The noise is the loudest on the control arm parts. Not on the strut tube. Very loud near the sway bar end link or the ball joint. Not as loud when I move away from these locations. At the strut top nut in the engine bay I hear the "swoosh swoosh" of the strut, but the clunk seems way far off. So if it is the strut cart. moving it should be loud here. I do love the stethoscope!

So two new theories:

1) The nut on the end NEW ball joint is loose?...whoops...(I did torque it) Oh maybe I can see if it moves...hmmmm

2) The sway bar end link is smacking the inside of the sway bar end hole?....whoops.....I crushed the heck out of the poly bushings with the air wrench last time I had the front end apart. I loosened the nut but the bushings look way deformed, and the clack is still there.

Can anyone help on this mystery clunk? Don, Steve, anybody???