I am rebuilding the front end of my car and I am replacing all of the front end suspension parts. I am about 70% of the way done working on the drivers side of my car and I am having problems installing the Bilstein HD strut.

I removed the strut assembly from the car and have it on my work bench.

The new Bilstein strut and gland nut is longer than the OEM Volvo cartirdge and gland nut. (I replaced these about 14 years ago)

I've checked the strut tube and there isn't anythink down there, like a washer or such. When I installed the new strut cartridge, I verified that it is at the bottom of the tube, however, when I go to tighten the gland nut, it is still 1/2" from being flush with the tube.

I have gone through the articles on this website and other websites and I can't find an answer to the problem that I am experiencing tonight.

I am stumped and would appreciate your ideas. Thanks!

P.S. I have verified that the part number is correct for this model (F4 P36 0081 HO)
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If it needs to be maintained, repaired or replaced on a 1990 240, I've probably done it. '90 240DL, 254K looking forward to 300K badge (or sticker??). >>You haven't really worked on a car until you draw blood<< :-}