XC90 AWD Repair

[4wheeldriver]

Whats up with the box? or have I missed it elsewhere?

[GSMGuy]

Nothing - at the moment - just hedging my bets, if I decide to go down the MQ route with Black Horse....

Wheel bearings are todays issue

Mike

[RoyMacDonald]

Originally Posted by GSMGuy

Roy, just because I have it in front of me lol...

A quote, from Rybrook to supply and fit an exchange gearbox to my XC90 D5 - ........



Mike

Hi Mike

£1500 was the 2008 price for replacing the Haldax transfer box. Not the gearbox. That price for the gearbox would be a bargin wouldn't it? :-)

All the best.

Roy

[GSMGuy]

Wasn't aware the transfer box could be replaced seperately, that price I listed is for a complete gearbox assy, which includes the transfer box...

Not sure about the TC though...


Mike

[RoyMacDonald]

Originally Posted by GSMGuy

Wasn't aware the transfer box could be replaced seperately, that price I listed is for a complete gearbox assy, which includes the transfer box...

Not sure about the TC though...


Mike

Hi Mike

A few people have had just the Haldax box replaced, although quite a few people have commented that although a lot of main dealers replace it, in fact it's only the splined collar that needs replacing at a cost of about £150.

There's a photo of the box on it's own here (the sixth one down)......http://www.volvoforums.org.uk/showpo...1&postcount=15

All the best.

Roy

[appahman]

QUOTE=Rockhopper;480423]As has been said many times before on this forum, the AWD system, as designed by Haldex - to include rear coupling and front bevel gear - is pretty much bullet proof.

What I'd still like to be confirmed is who designed the splined sleeve that essentially connects the transmission to the AWD system? Volvo or Haldex?

It's this sleeve that's the weak link and I would suggest the vast majority of any AWD 'failure' is attributed to this - NOT any failure of the bevel gear. When dealers replace the bevel gear its because they cannot release the sleeve from the bevel housing, hence asserting that you need a whole new bevel gear. (Do they all have the correct Volvo puller tool I wonder?).[/QUOTE]

Salutations from across the pond. I hope you all can help me here as I am new to the forum. I was trundling along the motorway at 65mph and I heard a loud BANG followed by lots of metal against metal and clunking... climbing under the car I found that the rear propshaft was loose, more loose than I expected it to be. the angle gear housing had been leaking for a few months but I thought nothing of it other than I'll get to that in a bit, but alas I think I may have bought it. the most interesting thing is that I didnt lose Front wheel drive, I drove the car home after seeing that it was probably the propshaft come lose, I drove it nearly 15 miles to my home to inspect it further, a bit noisy but totally smooth and drivable..


does anyone have pictures or experience with this propshaft to let me know that this should be loose? also does anyone have an expanded drawing or something scrawled on a napking to let me know where I should look for this and what the angle gear really looks like in a xc90

I have a '04 xc90 76,000 miles AWD T5... the estimate I recieved was that the gearbox as a unit could be bought for 1600 or I could have the dealership replace for nearly 4000 USD (2500 GBP)

I would like to know where this coupling should be located? is it within the housing? or does it connect the propshaft to the housing? or does it connect the angle gear to the axle within the housing.

one last thing, I can reach under the car, and turn the propshaft by hand easily, does that mean that the bevel is toast or the coupler?

sort of looks like this:

[appahman]

anything?

[RoyMacDonald]

Originally Posted by appahman

anything?

Check out the link in my last post. It has a photo of the spined sleeve and you can kind of see where it is. Yes that is the position you think it is. There are also photos of the new improved part.

The oil leak is a known fault and Volvo have issued a technical brief that shows how to fix it from the outside. I know it's a bit late now but is should be fixed straight away as if the tranfer box runs out of oil it gets hotter and hotter in use and you know only too well what happens next.

If you can get the old sleeve out you may get away with just the sleeve.

There are drawings of the insides of the Hadax box on the Haldax web site, but to acess some stuff you need to join their Haldax owners online club. ( totally free.)

All the best.

Roy

[appahman]

Ok Gents, this case is TOAST!

the ring and pinion inside are completley fragged, the bearing in the output starved and siezed tight... KABOOOM!

I'll upload pics of the carnage later..

[appahman]

so off to the boneyard to find a new-to-me case

file this one under ... failure to retain grease, and definetly not collar failure.. it looks like the upper bearing starved for oil (output side) and then sploded all over the place.. then the rollers lodged in the ring and pinion, giving it that awesome "clearanced" look...