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I endorse all previous posts on this thread. I do have tips to offer from notes I made doing strut insert changes on four Volvos in the past three years. The attached link captures my experiences.
http://sites.google.com/site/mdmet68/home/volvo-240-strut-notes
I never felt an urgency to get this job done immediately. Planning to me was most important to ensure safety and a smooth process.
I don't attempt to enter the debate about the best strut inserts to use. As for other parts, I would encourage Volvo OEM. Next, a good choice of tools is important. You'll save a lot of money doing this job yourself, so you might be able to spend a little on tools. You can rent for free a spring compressor from AdvanceAuto. Air impact wrench is a huge help. A 15/16" offset is useful. Instead of pipe wrenches, I went with spanner wrenches with cheater bars. I fashioned together rigs to stabilize the strut assembly. Found a away around moving the strut assembly in and out of the wheel well and guiding the assembly up into its tower mount.
And of course, PB Blaster! Mostly directed on to the gland nut and threads even a week up to the day of work. Excessive rust was not my issue.
Hope this helps you.
For the fun of Volvos,
Mike
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'92 245DL, '90 760 GLT
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