DIY AWD repair instructions - Unable to reply to that post?
 

Hi - sorry for creating a new thread, but I'm unable to post in the original one.

As I need to tackle replacing the splined sleeve, I have a few question for the original poster:

Do you have the part number of the splined sleeve kit ?

You said you cut a notch and used a crowbar to lever out - I've seen others who have drilled a hole through both sides of the sleeve and used a puller to get it out - do you think there is room to do that on the xc90 ?

Cheers,
Tim.

Hi - just fyi - I think once threads are in the articles section, they are there for reference only, ie not for general chatter or discussion.

I did ask the OP for part number of kit, but it was not available and he suggested you speak to Volvo with your VIN or reg number.

David

I tried to get back into the post to make some amendments and correct some typos but couldnt.

To answer your question, Volvo pn for the kit: V30787988 £80.50 +vat
I wouldnt suggest you use it to order the spline for your car. This part number was specific to my car (2005 D5 163bhp Geartronic). The PN might be different for your car. You sould really go in armed with the VIN or Reg.

I saw the posts with images that you refer to with the drilled holes. If you have a good drill and can hold it steady to go through hardened steel, then go for it. This seemed too much hassle for me as the sleeve was stuck in the transmission. I initially cut a shallow notch with an angle grinder and walked it off with a pry about an inch. (see image) This got harder and harder, so I gave up and cut right through the first notch and hooked on my slide hammer. I wish I had done this first. By far the easiest and quickest option.
No heat or WD40 was used to remove the spline. I'll be damned if you can get a puller onto the transmission without removing it.

I would add to my original post that I replaced the bevel gear fluid. It drained 700ml and there is a clear notch marked on the unit as a maximum. The replacement bolts in the kit are 13mm headed as opposed to the 14mm one removed.

I can also report that all my wheelspin has disappeared. I have tested the car up in the air and all four wheels rotate when in drive.
Reassembly took just 2 hours in total because I knew what I was doing. The disassembly took longer because I was working off the cuff and without instruction
I am happy to answer your questions as you tackle this job

Many thanks for the additional info D5gill. I'll probably be tackling this sometime next week, so thanks for the offer of advice.

Not sure if the Nottingham dealer was correct, but they told me that the T6 doesn't have the splined sleeve, and so doesn't have the problem. Can anyone confirm this?

[QUOTE=D5Gill;767899]

I can also report that all my wheelspin has disappeared. I have tested the car up in the air and all four wheels rotate when in drive.


From a previous thread - many, like myself experience slight wheel spin away from junctions (especially when the wheels are turned) before AWD is engaged - must say mine feels like more than 1/7th of wheel turn as stated, but I definately still have AWD - but could this be a sign of impending failure?
When you say NO wheelspin - is this No?

Can you also confirm if yours did 185K miles on original sleeve before failure?

According to my copy of vardis the T6 has a chain drive arrangement instead of the sleeve.

The last time I was able to check that AWD was over a year ago at 130k miles during snow. All was well. 20k miles later, In January of this year, during the snow, it was very obvious that my AWD was not working. All I got was FWD wheel spin. So for the last 30k miles or so, I drove in knowledge that the sleeve had definitely failed. This was confirmed by horrendous wheel spin in the wet when pulling away at junctions.

For the last few hundred miles or so (in plenty of wet) my wheelspin has pretty much gone. The car feels more composed on the roads. If the fronts have spun 1/7 a rotation, then I have not felt or heard it.

The sleeve/collar was the original unit. It had done 130k miles the last time I could confirm that it was good. Once I had removed it, it was pretty obvious what had killed it - Rust. The splines inside the collar were covered in corrosion which had caused the surface to weaken. This progressively got worse until the splines were all but gone. The new collar apparently is much harder and has a higher tensile strength. This coupled with the grease, will prevent corrosion setting in for the foreseeable future.

I am glad that I got this job done in time for the winter. I will have a lot more confidence when driving in adverse conditions.

I can't believe that people are having to change their transmissions and bevel gears just because the mechanic could not release the bevel collar. Sheer laziness, lack of trying or bumping the bill is what springs to mind. Releasing the collar was one of the easiest jobs in the whole process. Anyone who can change their own oil, do a brake job, cut a notch in the bevel collar with an angle grinder and unbolt ancillaries that are in the way can do this job.


GLAD THAT MY XC ISNT RUNNING LIKE THIS ANYMORE ¬

Any chance we can get this thread merged with the main one in the Articles section?

Just a post fix update:

1600 miles later on the new spline collar and average MPG has dropped from 33.2mpg to 30.3. Same driving style same journeys - The cost of 4WD is a 10% drop in fuel efficency