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1.Ok so my concerns. Can't figure it out.
Today when i was in traffic, stop and go. I was pressing on accelerator lightly to gas and to complete stop heard little, let's say, clunk when gear was engaging( transmission mount?) And when braking from 10mph.
2. When on highway going about 65-70 mph car steers on its own to left to right not a lot but enough where I have to correct it lightly, on concrete with stripes going forward I understand. But on normal asphalt it does it.
3. Sound like right strut is making klunk noise on potholes ( strut mounts?) OR the strut going out?
4. Some klunk in the floor on some potholes and stopping.in the middle of the car.

5. Stock suspension, feels like riding on coilovers, aka feel every little imperfection on the road. But still stiff and stable, not bouncing.
6. When it's freezing outside, below 32f. When hitting a speed bump at like 5 mph, I hear rubbing or the "hrrr hurrr" sound on front struts when car bounces down and comes back up from speed bump.
It a 2004 s40 t5 r design. I took a lot apart, but visually everything looks alright. I'm not an expert on volvo, vw mostly but this just can't figure out. And replacing all bushings, struts and mounts is just way too expensive. Where should I start. And if someone can send me link for strut mounts, bushings, that fit my car. I would really appreciate it. Or if there is a volvo mechanic in colorado, I would take my car for diagnostics. Let me know. Thanks guys and gals

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What usually helps me is it jacking the car up and holding each bushing and joint and have a friend kick the wheel and see if I can feel any movement. Sometimes a ball joint or tre will be bad without torn boots and the only way to tell is to feel it or get a bar in there and pry on things and see if they move. To me it sounds like sway bar links, torque mount, and inner or outer tie rods, but its hard to tell without actually seeing the car.

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How many miles? If it's all original, it probably needs a nice refresher on suspension. Control arms, end links, all mounts... Etc.
 

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As has already been mentioned many of the symptoms you describe cover sway bar end-links, swaybar bushings and struts and motor mounts. Unload the front suspension by putting both sides on jack stands and grab each end link and lift and turn to check for play. I had Toyota that was especially noisy and clunked going over speed bumps. It had bad end-links and front sway bar bushings, replaced both and made a big difference. Also while front suspension is unloaded grab each wheel at 9 & 3 and 12 & 6 and check for play.

I'm new to the Volvo ownership, I purchased a 2004.5 T5 with 120K miles in September I knew it needed right lower control arm. Replaced it, but also had to replace right upper motor mount which was bad. Noticed right strut leaking oil. Replaced both struts. Left turned out to be dead as well even though no leaking. If the struts aren't leaking oil it is hard to know if they are bad or not, but it is probably time to change them. I decided to replace the left lower control arm, glad i did because the busing was bad on it as well. The lower nuts on both of the sway bar end links were stuck and even PB blaster couldn't get them off. Had to cut them off. If you replace the lower control arms, that's the time to replace the sway bar end-links. With the control arms off you have much better access to lower nuts
 

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I had to cut my sway bar links off on my xc90 too. The bolts freeze up and the balls get loose, so it just spins. So if you're going to do it, don't struggle with it if it's frozen just get the 10 dollar harbor freight angle grinder special if you don't already own one. I've got one and its great for like a couple dozen uses, and then they die lol.. I'm replacing it with a craftsman c3 one cause I already have the batteries.

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Engine mount could be the cause of the clunking in stop and go. When I took my car in for a timing belt service around 117k, the passenger side engine mount was found to be torn and leaking oil. Much smoother with the replacement. Cost ~$120.

As for mechanics, I'll happily give Swedish Motors in Boulder and Carl Duke in Ft Collins my business. There's also Volvo Specialists in Denver (haven't used them personally, but I've heard good things).
 
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