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Boy, that's a lot of questions. I can't answer all but you raise some fundamental issues about the purchase and use of tools. In the case of the Volvo special tools, some of them are a specific size to fit the need while generic tools may not be. For example, the tools used to press in or out the suspension bushings are an exact fit. My use of pipe fittings and sockets meant that I had to search quite awhile to find the right size and could not always find one. There's no way a Volvo shop would take that time.
Another issue has to do with the DIY's frequency of use and budget. I saved enough on replacing the rear bushings in my 240 to pay for the shop press and rear suspension bushing tool, and the parts. As you mention in your discussion of buying a transmission jack, this seemed like a good way to go although it was still a tough job. If I wanted to hold the engine while doing a tranny removal, I'd build my own holder since I'm sure it would cost less and be just as usable. When I buy hand tools, I try to buy decent quality for frequently used ones such as wrenches and sockets but I can't justify professional grade such as SK or Proto. I buy Craftsman and I've tried some Chinese wrenches and found they hold up to my use just fine. A professional mechanic would probably go with the more expensive tools since they have to stand up to harder use and have to last.
You ask why I won't do the rear seal. It's purely personal. I know how, but I'm getting a little too old (70) to work under a car and have a medical problem (vertigo) which makes it hard to work there. The last two times I did a clutch job I bench pressed the tranny back up onto the bell housing. What a job that was! I should have gotten a tranny jack but was on a real tight budget.
You asked about air tools. I've only limited experience with them but can say this much. Don't scrimp on the compressor. My old compressor lacked the capacity to run an impact wrench for more than a few bursts at a time. I ended up getting a larger compressor. Also don't scrimp on the impact wrench. I bought an inexpensive Chinese one and it can barely take off lug nuts. It was very useful in removing the top strut nut when a manual strut tool just shattered on my 5th strut removal. I find I don't use the air tools much but that may be habit. If you have much rust on your suspension fittings, I'll bet the impact wrench would be a great help.
Lastly, please let one who has reached senior citizen status in one piece, more or less, suggest that you not take offense at replies to your questions. I have found over the last few years that folks on this board are really trying to help. Sometimes you'll get a flippant answer or one which doesn't get at the question the way you'd prefer. You may need to rephrase your question and ask again. There's no call for flaming and I've seen boards where this happens and I won't go on them. You ask some good questions about the special tools and I'm interested in the answers.
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