D5 in XC90 engine malfunction when towing
 

Has anyone experienced the following as the Volvo specialist I use is baffled....
It's an 2006 XC90 163bhp but remapped by Rica to 182.
The garage has replaced a fuel pressure sensor and fuel pressure regulator to eliminate the problem that when accelerating hard it reverted to limp mode. These measures cured that problem, in the meantime I have also had the torque converter reconditioned as the clutch lock was slipping. But recently I started towing a caravan and found that at cruising speeds 55-60 mph if I reached an incline and tried to maintain my speed by accelerating a little it would display; 'ENGINE SERVICE REQUIRED URGENT' and revert to limp mode. However, pull up, switch off, restart and it would pull away without any problem. And it would drive on A & B roads at lower speeds without a problem, seems only to occur at about 60 mph when the clutch lock is engaged and the engine is running at approx. 2000 rpm.
The problem appeared to have been isolated to the fuel pressure safety value because when under load the fuel pressure was peaking too high causing the car to shut down and revert to limp mode. This was replaced £300 later - ouch!
BUT, all was good on our next trip with the caravan until about an hour into the trip when again when under load it cut out reverting to limp mode. However, again, pull up, switch off, restart and it will pull away fine. (Not fun on a French auto route with no hard shoulder...) But its still OK at lower speeds on minor roads, would pull the van up the side of a house!!
To work around this problem when cruising I can maintain 60 mph but when I reach an incline I have to maintain throttle, allow the speed to drop away until the clutch lock disengages, the revs increase to 2500 rpm and I can then accelerate, but if I over do it and I hit 60 mph which re-engages the clutch lock, the revs drop back to 2000 rpm there is then a risk it will just cut out....
Bit long winded I'm afraid, but this is now really frustrating as the car is superb without the van, but the extra load of the caravan at cruising speeds just doesn't agree with it.
Anyone had a similar experience?

It sounds as if the lock up clutch is slipping , the stored fault code should confirm this . Have you had a gearbox software update from your dealer ? That is well worth it .

Thanks for your suggestion. The torque converter was recond prior to this condition because the clutch lock was slipping, evident by a judder in the transmission at about 55 mph.
The fault codes prior to the fuel pressure safety valve being fitted indicated a fuel pressure issue. But as the fault has reoccurred I will obviously need to get the fault codes checked again on the next visit to the garage.

Hi - I have a similar issue with my D5 XC90 - at around 2k revs for a prolonged period of time I trigger the limp mode for the gearbox.

THe fault code is TMC-002F

I already have the latest TMC software according to the dealer. ATF has just been flushed and I've suffered it since.

Fault code is lockup function slipping or not engaged.

ANy ideas?

If there is any issue concerned with the clutch lock I suspect you will need the torque converter reconditioning. I had mine done which cured the problems I had with the gearbox box causing the car to go to limp mode. It wasn't a cheap repair all up it was about £1,200 and they also wanted to strip the whole gearbox in case pieces had circulated round the box. I declined this extra work and took the chance as I couldn't justify the £3,500 cost of a complete reconditioned gearbox. Fortunately I haven't suffered any further issues with the box, just this problem with the towing.....
One piece of advice, don't go for a cheap rebuild option, I heard many tales of poor workmanship which failed to resolve the problems. I used Charlwood Volvo near Gatwick who remove the box but they use a specialist for the reconditioning of the torque converter/gearbox.

I assume thats from volvo , as that is the price .. the box is basicly new .. i would never pay that to anyone else to " recondition " ...

I've been quoted £1400 for recon gearbox supplied and fitted with 12 months warranty from a specialist.

If the cost of trying the solenoid replacement is anything over £200 I might just get the box done.... At least then I know there'll be no issues

You may have checked this but my xc had EXACTLY the same symptoms you described , and it was simply the swirl valve arm had fell off
Dave

Dave.. Who was that reply for?

this
"towing a caravan and found that at cruising speeds 55-60 mph if I reached an incline and tried to maintain my speed by accelerating a little it would display; 'ENGINE SERVICE REQUIRED URGENT' and revert to limp mode. However, pull up, switch off, restart and it would pull away without any problem"
this, I thought it was a blocked fuel filter at first , so changed it , searched the forum and found the swirl arm problem, checked mine and the arm had come off

we got back from the Cotswold driving as you did on A roads to get us home.
Dave