AWD Transmission: how many of you have suffered AWD system issues?

[Tostik]

Hi, all. My first post. I've enjoyed reading some of the threads--very educational.

I own a 2006 2.5T AWD XC90 with 72,000miles manufactured 09/05, so I guess I have the weak spline sleeve. Just drove my XC90 in some slick snow by my house, and up a steep embankment to get back on my driveway (in Colorado). I know my AWD is working. I think I would like to take RoyMacDonald's advice and get a new spline sleeve, but I know my independent Volvo mechanic is going to say it's not necessary. He's an extremely competent mechanic who charges less than most independent Ford mechanics. He's one of the main reason I own 3 Volvos. He looks out for my Volvos and has given me a few small jobs for free. But I know he's going say, "It's not something you need to do--we'll just keep an eye on it". I may have to insist.

[RoyMacDonald]

Originally Posted by alfahta

£195 (labour volvo specialist) + £90 for the splined sleeve from Volvo

It isn't for the T6. :-)

[Carrizos]

Originally Posted by RoyMacDonald

The ATF should be changed every 48k or 4 years. The filter is felt and when it gets clogged up it's a strip down job to replace so it needs all the help it can get because the oilways in the valve body are very fine and easily blocked.

My XC90 diff is being replaced just now, is that likely to involve replacing the ATF as well? it looked a dirty red/grey to me not the nice clear pink/red it should be. 53 plate 53k miles bought this Jan. Its disappointing to need major parts replaced already, not impressed with the build quality. I guess I should ask them to replace the sleeve as a precaution but the AWD seems fine at the moment.

Morris minor diff - 800k+miles with no probs, Mondeo 2.5 240K miles no probs, Mitsi Delica Diffs 2 vans 200K / 150k miles each with no probs despite lots of tough offroading and heavy towing.

[RoyMacDonald]

Originally Posted by Carrizos

My XC90 diff is being replaced just now, is that likely to involve replacing the ATF as well? it looked a dirty red/grey to me not the nice clear pink/red it should be. 53 plate 53k miles bought this Jan. Its disappointing to need major parts replaced already, not impressed with the build quality. I guess I should ask them to replace the sleeve as a precaution but the AWD seems fine at the moment.

Morris minor diff - 800k+miles with no probs, Mondeo 2.5 240K miles no probs, Mitsi Delica Diffs 2 vans 200K / 150k miles each with no probs despite lots of tough offroading and heavy towing.

No. Which diff are you talking about? Rear axle? They normally last forever. It's just bad luck if your's has failed early. Assuming no oil leak that is. Same with the front angle drive, it's usually down to an unoticed oil leak.

Don't try and do more than 55k on the original sleeve. That's the point at which the original sleeve generally starts to fail, after that it's a matter of luck. The uprated sleeve kit isn't that expensive.

[Carrizos]

Rear diff, I couldn't see any signs of an oil leak neither could the dealer, he did say it is a pumped oil system and the pump was not showing any faults - hence my wondering if it shares fluid with the transmission. Not sure about luck being a cause of anything, maybe bad luck/judgement I bought one with this problem though. There is usually a reason for failure and often it is due to abuse. I have witnessed a rear diff going under heavy towing conditions off road - hauling another 4X4 out of a steep ditch. There are Youtube clips of this happening as well. http://www.youtube.com/watch?v=olDpN7dkl0Y

I will order a sleeve and fit it before we head off to Spain, we will be going a few places where we would not get out again on 2WD.

[RoyMacDonald]

Originally Posted by Carrizos

Rear diff, I couldn't see any signs of an oil leak neither could the dealer, he did say it is a pumped oil system and the pump was not showing any faults - hence my wondering if it shares fluid with the transmission. Not sure about luck being a cause of anything, maybe bad luck/judgement I bought one with this problem though. There is usually a reason for failure and often it is due to abuse. I have witnessed a rear diff going under heavy towing conditions off road - hauling another 4X4 out of a steep ditch. There are Youtube clips of this happening as well. http://www.youtube.com/watch?v=olDpN7dkl0Y

I will order a sleeve and fit it before we head off to Spain, we will be going a few places where we would not get out again on 2WD.

Still not sure. I'm pretty sure the rear diff isn't pumped and dosn't have ATF in it. Somone did post on here about a failure but that was definatly lack of oil causing it to run red hot and wreck the rear axel. (He ignored the leak and carried on running till it blew up )

The Haldax unit has a pump but it also dosn't have ATF in it. It uses a special oil only available from Volvo. The Haldax unit was made by Haldax and now by Borg Warner. The electonic unit on the side of it is more likely to develop a fault than the mechanics. The electronic unit is repairable.

When I say bad luck I mean that all electronics and mechanical parts have a small failure rate. No manufacturer in the world makes totally infalible components. I recently bought a Ctek charger who have a 2% quoted failure rate, which is regarded as extemely small. I was unlucky in that I got one of the 2%. The replacement was fine.

[Carrizos]

Ah I see what you mean by bad luck and thanks for the other info. When the problem was first an issue I queried the safety aspect of continuing to drive the car as I have a friend who had a diff seize and his car spun. The mechanic I talked to said that as long as there was not a fault with the pump the diff would not seize and it would be safe to drive. he then plugged in a computer and told me the pump was fine. I think I will be taking it elsewhere for a second opinion / check for other faults when i get it back.

Looks like I might be piddling about changing the ATF in the next few weeks as well, very glad there is a lot of info on how to do that via this forum...thanks again much appreciated.

[RoyMacDonald]

Originally Posted by Carrizos

Ah I see what you mean by bad luck and thanks for the other info. When the problem was first an issue I queried the safety aspect of continuing to drive the car as I have a friend who had a diff seize and his car spun. The mechanic I talked to said that as long as there was not a fault with the pump the diff would not seize and it would be safe to drive. he then plugged in a computer and told me the pump was fine. I think I will be taking it elsewhere for a second opinion / check for other faults when i get it back.

Looks like I might be piddling about changing the ATF in the next few weeks as well, very glad there is a lot of info on how to do that via this forum...thanks again much appreciated.

Be a bit cautious about advice from garages on the AWD system. The guy who had his rear diff blow up rang his local dealer about oil leaking from the rear axle and was told it was from the Haldax unit and it wouldn't be a problem as he would just lose rear wheel drive as the Hadax unit had built in protection, (which it does) and to carry on using the car! In fact the oil leak was from the diff. (The Haldax unit is bolted to it) which ran red hot and took out the Haldax unit, the rear axel and propshaft.

I'd stick to specialists with a good knowledge of the AWD system if I were you.

If the propshaft is removed it makes sense to replace the sleeve at the same time. The angle drive needs to be removed as well because the sleeve is inbetween the the angle drive at the front and the gearbox. Unless you have a T6 in which case there isn't a splined sleeve.

[Carrizos]

Ouch that sounds nasty, I went back to the dealer I bought it from as I became suspicious of the noise it made within a few days of purchase. I was under the impression that was what I had to do - give them the chance to rectify it. They present themselves as a 'new and used Volvo specialist' but I am now not so sure about that claim. They have been very nice so far I will give them that but I will go to another specialist for a once over when I get it back - any recommendations in or near Sussex/Surrey would be appreciated. I believe I have three months statutory fit for purpose/no quibble warranty, there is also a 12 month warranty but I want everything sorted before the three months are up.

Not a T6.

[RoyMacDonald]

Originally Posted by Carrizos

Ouch that sounds nasty, I went back to the dealer I bought it from as I became suspicious of the noise it made within a few days of purchase. I was under the impression that was what I had to do - give them the chance to rectify it. They present themselves as a 'new and used Volvo specialist' but I am now not so sure about that claim. They have been very nice so far I will give them that but I will go to another specialist for a once over when I get it back - any recommendations in or near Sussex/Surrey would be appreciated. I believe I have three months statutory fit for purpose/no quibble warranty, there is also a 12 month warranty but I want everything sorted before the three months are up.

Not a T6.

I always go to Charlwood Volvo for all the work on my Volvos. http://www.crvolvo.com/ The Google map is wrong by the way the workshop is on the other side of the road and a bit further South than shown.