First, thanks for everyone's help getting me to this point. I have rebuilt our 91 240's front suspension replacing all bushings and ball joints, rear suspension including all bushings, shocks, and coil springs, driveline ujoints and center bearing, and replaced the transmission mount all with Brickster input - you guys have been extremely helpful. Motor mounts and valve adjusting will wait till next weekend.

I've got an annoying problem... I first tried Bilstein touring shocks in the rear, but got a rattle. Bought Boge automatics - same rattle. Clearly not the Bilsteins. I have replaced newly installed rubber torque rod bushings with urethane, and spent most of this afternoon shimming the Boges with aluminum tape. Still rattling.

Everything is torqued right with the vehicle weight on the wheels. The upper shock mounting studs are tight to the sub-frame. The only thing left is that I bent the axle flanges that hold the rear trailing arm bushings inward slightly......toward the center of each pair. I looks like this would reduce the potential for contact with the trailing arm.......

I know I got the rear trailing arm bushings in right-side up. Is there a backwards?????? They appear to be tapered slightly.....

Any help would be appreciated. The car rides fantastic at 135,000 miles - it's like it was when we bought it in '91 - but the slow-speed rattle is annoying as heck.

Thanks again for all of the help!

David