Front Strut Noise and Failure Issue on Volvo S60

Average mileage: 103,638 (150–228,000)
3 model years affected: 2002, 2004, 2007
12 people reported this problem
10 people shared problem details
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.
2004 Volvo S6090,000
when traveling over light bumps there is very noisy metal on metal and nashing sounds from passenger side . under engine hood at the top of strut the the round part turns by hand .
2002 Volvo S60228,000
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!
2007 Volvo S6060,000
Right front end speaking when going over rough pavement. Intensifies in cold weather. Almost gone in warm weather. No one able to diagnose it accurately. Must be the strut but what about all the assembly parts that are needed for repair? Tx Joanie
2002 Volvo S6099,000
Driver side suspension made noise since I bought it at 94,000 miles, just discovered driver side strut bearing broken, strut poking through and scraping the hood. Passenger side bearing still intact but worn, will probably replace both.
2007 Volvo S6094,064
Strurs are leaking and making noise
2004 Volvo S60150
Hit small pothole, rattling and crack noise. Now feels shakey
2002 Volvo S60165,000
Strut on my car is very loose if u push on my tire u can see it move
2004 Volvo S60139,000
This problem began a long time ago. I could hear a horrible grinding mostly coming from my passenger side. Jacked the car up to see the strut was ripped and not properly connected anymore. Replaced the strut myself. Terrible grinding stopped for awhile and same noise began on my driver side. Was pretty aggravated and still don't have time or money to currently fix it. Now when accelerating car shakes violently and does not steer well on highway. Husbands 1991 Honda Accord with 220,000 on it still has original working struts. Switching to Honda. Turns out I cannot afford this low level sedan.
2004 Volvo S6079,000
Same problem with struts. Vehicle handling was altered and thought it could be air pressure. Turned out it was struts needed to be replaced.
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