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No offense taken, Bruce. I understand your words of caution and appreciate that safety is always first (I am a supervisor in a manufacturing environment and work with heavy equipment every day).
I have the spring compressors for the struts ready to go. I read on the internet about a fellow DIY Volvo owner who had made a tool by bending a 15/16" open-end/box end (http://www.homestead.com/volvo2/240struts.html). I tried to make the same tool, but there wasn't enough clearance around the nut for my tool. I will probably try to make another tool, but was wondering about others' experiences. I do have a Chilton's manual, which specifies the steps to the procedure, and have researched the procedure extensively on the internet, but I can't find the metric size of that nut, and I was hoping for that information.
I am removing the struts so that I can install the following:
1. New sway bar bushings (I am also missing one of the mounting screws - very noisy clunking!)
2. Lower ball joints, hence the need to remove the strut towers. I have a good pickle fork, but may need a puller for that joint.
3. Control arm bushings.
4. I will inspect the tie rod ends, wheel bearings, shock absorbers, coil-springs and bumpers, bleed the brakes, inspect the discs, pads and brake lines.
5. I will drain the transmission and OD unit and replace with new ATF or maybe Redline MTL. I do have a problem with the OD; unbeknownst to me, the previous owner wired the OD solenoid directly to a toggle switch on the dash, effectively bypassing the 4th gear switch. I have operated the car in reverse, which has caused some damage, how extensive, I do not know.
I do have more work to do on this project, and certainly appreciate all of your advice, experience and concerns.
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