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I tightened down the tube nuts until each one hit a definite stop. Even so, they each have 2-3 threads still showing.
When I bounce the car, I can hear and deel the clunk at the piston top nut, or somewhere in the strut bearing area. Looks like the nut on the piston there is also moving sidways a bit.
My main focus now will be to replace the Volvo bump stops and sleeves with a set of KYB strut bellows. I have a feeling the Volv stops, which are in between the piston journal and the spring top plate may be preventing the piston from reaching the needed height to get properly clamped by the top nuts.
When I use the KYB belllows, I'll omit the washer (which would also sit on the journal) and just slide it down the piston so it protects it. The top of the bellows will be below the spring top plate and the journal should fit up through the top plate and into the strut bearing.
This makes sense.... It is only the threads (thinner diameter than the journal) which are through the strut bearing at this point. that is allowing a sideways movement in the top of the piston.
Good theory, anyway.
Maybe when Bently's says to eliminate the bump stop when using gas inserts, they understand that the journals are different (just one journal) on the gas cartridges compared to the oil inserts (two journals)
Ths bump stops on the oil filled inserts would slip down past the uppermost ournal and rest on the thicker journal below. That leave the upper journal to pass up throught th strut bearing and get clamped by the top nut.
Whatever the case, I need to do thins entire job a second time now. Stick around. It will take a couple of days before the bellows arrive.
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