Report: Front Strut Noise and Failure Issue
Volvo S60 Problem
Model Year Affected: 2002
Average Mileage: 176,500 mi (125,000 mi - 228,000 mi)
Front struts are a real issue with the S60. I have a 2002 with 125,000 and just had the OEM struts installed a year ago by the dealer and they are already failing. The top of the strut is actually separating at the top and is visisble if you look at the strut tower from under the hood. My local repair shop reports actually seeing one break through the top and come through the hood. Dealer is telling me because the struts were put in 13 months ago they are now out of warranty. BEWARE: even the OEM struts will prematurely fail, not just the Chinese junk parts. Volvo knows about this problem and needs to take responsibility.
To address the question about replacement. When replacing the struts, the top caps must be done also to eliminate the rattle sound. Even with new struts and CV joints the front end will still make noise. The design is very poor and shifts using the struts as the pivot point, so failure is the only option.
Visitor, 2002 Volvo S60, 228,000 mi
The front right strut on my vehicle actually protruded through strut mount and pierced the hood causing a dent and cracked paint. I fixed the problem by replacing the spring seat. Although that's fixed, I still have a dent and cracked paint!