Volvo S60 (2000 - 2009) - 2002 D5 Boot strut replacement: DIY job?

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Tue 23 Dec 2008 22:15
2002 D5 Boot strut replacement: DIY job? - Brian Tryzers
My 52 reg S60 has broken another boot strut. This happened on both sides when the car was new, and I had them replaced under warranty. Now, five years on, it's happened again - the plastic socket on the slidey end has come apart and is no longer secure on the knob that protrudes from the bodywork.

Looking at it, it seems to me that it should be a simple job to replace - get new strut from parts specialist near my office, maybe a tap with a mallet to remove the unbroken end from its knob, then the same in reverse to push the new one into place. Is this so, or am I missing something terrible that's known only to Volvo main dealers?

Edited by Dynamic Dave on 24/12/2008 at 00:35

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Tue 23 Dec 2008 22:20
52 D5 Boot strut replacement: DIY job? - mfarrow
It's pretty much how you describe. Some have a spring clip which fits over the ball joint, might have to pull this off to unclip.

Make sure you've got something (your head and a cushion?) to hold the boot up - they're surprisingly heavy! Certainly only do one side at a time.

I bought genuine from Ford not that long ago - about £40 each side, though that's double what you might find at a 'specialist' but guaranteed it is the right one.
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Sun 28 Dec 2008 09:19
52 D5 Boot strut replacement: DIY job? - Brian Tryzers
Thanks for the encouragement, MF. I'll get it sorted this week.
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Mon 29 Dec 2008 08:35
2002 D5 Boot strut replacement: DIY job? - Victorbox
As I'm about to do this job on a Cavalier (which is the prise up clip variety) would anyone recommend a blob of grease on each metal balljoint before fitting new strut?
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Mon 29 Dec 2008 11:10
2002 D5 Boot strut replacement: DIY job? - mfarrow
I doubt if even NC would object. I didn't do it though.
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Fri 2 Jan 2009 10:47
2002 D5 Boot strut replacement: DIY job? - Brian Tryzers
Well, I talked to the 'specialist', and by the time they'd added their carriage charge for a special order (for which they wanted payment in advance) it was going to cost me more than buying the part from my Volvo dealer. So I have the Volvo part on order (£39) and I'll fit it next week.
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Fri 2 Jan 2009 13:43
2002 D5 Boot strut replacement: DIY job? - Number_Cruncher
>>I doubt if even NC would object.

No, no objection here!

However, I think that the boot hinges are usually much more in need of oil than the struts - I've seen some cars where the roof flexes because the hinges are so tight with rust, while I can't remember any problems with the strut ends.

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Fri 9 Jan 2009 23:11
2002 D5 Boot strut replacement: DIY job? - Brian Tryzers
Just to put this to bed, I got the part from the dealer (who'd rung to say it was in) and paid on collection, not in advance. Removing the old strut took a couple of minutes' proggling with a screwdriver to release the spring clip from the remaining good end, then a tap with an 8oz hammer got the new one securely into place.

And, what do you know: each socket of the new strut already had a dab of grease inside!
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