AWD Not working on XC90
 

Hello

Wonder if anyone can help, Volvo dealer advises 'splines stripped on bevel gear connection to transmission' yet car drives perfectly well albeit just front wheel drive. Cannot understand why with this fault there is not a horrible noise and car being un-driveable.

Volvo dealer quoting nearly £600 for a fix.

Any advice welcomed.

Thanks

It is not uncommon, for it to go unnoticed for sometime....many won't know of the fault until the need to rely on the AWD system (in icy conditions or towing on muddy fields etc.)

have a read here:
http://www.volvoforums.org.uk/showthread.php?t=105769

and here:
http://www.volvoforums.org.uk/showthread.php?t=66098


As far as I'm aware you won't do any further harm driving it like it for the time being, someone please correct me if I'm wrong.

Sorry, you're wrong ;)

If the splined coupling is still in there, it's wearing away the splines on the shafts as well as it's own internal splines, this will then require a far more substantial repair, like a new bevel gear and/or gearbox shaft, than just replacing the splined coupling itself. Over a couple of grand for parts and labour....
Of course this assumes there's no damage to the shafts already, which is 50/50 in most cases :( Depends on how long it's gone undiagnosed....

TBH, £600 doesn't sound all that bad IF they're going to stick to it AND warranty the repair.

TiredGeek is correct.
My indy has fixed loads of these (12 to 15 in one year he said) at £1200 a shot - that's including the bevel gear also I think.

If £600 is what the dealer will charge, and if they will then guarantee the continuing health of your AWD coupling, then that might not too bad.

i have a xc90 at mo , cambelt was done at 80k its now got 130k would it need change ? sorry its diesel 2005 , also thinking of buying a second car what about the s40 r design 2.0 d r design ! whats your feed back on this car ?
cheers murray

XC90 AWD parts replacement
 

Anyone got any diagrams / pictures of the coupling and bevel gear and what is required to be stripped to diagnose?

If you do a Google search for 'volvo angle gear' or 'volvo bevel gear' you'll get a number of hits, especially from US forums. There are some with good instructions and pictures too.
Basically (and this is from a V70 AWD so an XC90 might have some differences), it's a case of disconnecting the propshaft at the front joint, removing the front right driveshaft and then removing the angle gear. The splined sleeve will either come out with the angle gear or be stuck on the gearbox/diff output shaft.

If you're really lucky, the only damage will be to the splined sleeve but don't count on it - to be that lucky you need to be able to get all six lottery numbers in every draw for a month or more.
The usual damage is to the sleeve and the angle gear input shaft, which is not available as a spare so you have to find a replacement anglegear of which there are a number of different versions - and only one of these types will fit your vehicle.
If you're really unlucky, there'll be damage to the gearbox/diff output shaft.

on swedespeed in the R forums there is a post talking about getting the collar drilled and welded to end the stripping once and for all. Just an FYI

Is this what you are talking about?

http://www.youtube.com/watch?v=4Af-4DhZ5p8