Thanks Weather and Andrew!

I decided to go ahead and install and see what happens!

Okay, here's what I have found out.

I called two of the usual mail order parts places and they were not aware that there was an issue with the Bilstein HD struts being too long for the strut housing.

I called Bilstein. Tech rep John was very polite and helpful. He returned my telephone call promptly. He was of the opinion that there is an insert that must be removed (like the parts places). I did exploratory surgery on my strut housing and can confirm that there isn't one in there. I checked three of them.

I went to the junk yard today and met with great success. I got an entire drivers side suspension assembly, a pink label ECM, an AMM and a power antenna for $76 including tax.

I ended up thoroughly cleaning the inside of the strut housing, removing the labels from the Bilsteins and then inserting them. After applying thread locker, I tightened the gland nut to hernia tight status. This leaves about 7mm of nut that is not making contact with the strut housing.

Hopefully, tomorrow, I will be able to finish connecting the brake lines, install the hubs (New Bearings and Races, plus new lug studs), rebuilt calipers, new rotors and pads. I've already installed all poly up front including the sway bars. I replaced the steering rods and end links, ball joints and strut bearings.

I can't wait to feel how she drives! I was really happy with the all poly rear bushings I did a few weeks ago.

Take aways:

If you have a 1990 240 DL, buy Bilstein HD's at your own risk!

Don't buy $1600 worth of parts and put off the job for 2 1/2 years. (I can't return the struts!)

Don't believe everything you read when it comes to parts that will fit your Volvo. I haven't had any problems in the past, but this was a real PITA!

Having the gland nut tool (IPD) was really nice. I didn't end up damaging the gland nut when I removed the old one or when I installed the new one.

When I was ready to tighten the gland nut, I wrapped duct tape around the strut rod, so that if my wrench slipped, I wouldn't scratch the rod. Thankfully, the wrench didn't slip, but I didn't want any more headaches!

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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<< :-}