I was just reading your thread about this issue!
It does seem to be an issue on some of these cars, however I broke up and scrapped a 2002 S60 with 200k on the clock that had been well used and abused and there wasn't any rust anywhere on it. I know the strut tops were good as I cut through both of them when I eventually chopped it up for scrap.
I'm undecided weather to repair or scrap mine. I think a £50 welded repair should do it, but it would look unsightly and of course I'd know there was still rust creeping away underneath in other areas.
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Tim
1968 Volvo 145 long term project.
Currently without a Volvo daily driver.
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