2002 XC90 D5 Auto The definitive AWD fixes

[Maccartw]

Dear Volvo lovers,

Thank you for the help you have been so far in bringing me up to speed with XC90 things; having come late to the club. I have discovered (courtesy of being code read and inspected at my local indy) she is missing her AWD this is listed as ANGLE SLEEVE DRIVE HAS STRIPPED.

Many, many, many, many posts listed here later my eyes and brain are stinging.

Could someone please give a more definitive answer to the fix. I have called Southampton Volvo and they have a sleeve at £272.00 but also a repair kit at £115.00 they were a bit vague as to which one it is.

1. Is it the sleeve i need or the kit
2. Does either of those prices sound (ballpark) right in relation to the problem
3. Could anybody please supply me with a video or picture/text guide link to repairing this myself.

Unrelated issue but useful for my beloved wife parking. Parking assist problems as well, no sensor fault listed on VADIS told probably the control unit- would you persist with new parts to get the old system working, clean the loom up removing dirt, damp etc or strip the old bits out and buy a £50 new 3rd party kit instead?

Kind Regards to all cherished helpers in this forum, it is appreciated.

[Maccartw]

Sorry, 2003 not 2002

[Tannaton]

I believe (but not 100% confident - please someone confirm) that the repair kit actually contains more parts than just the sleeve - i.e. seals, grease, washers etc. There are a few Volvo anomalies where repair kits are cheaper than single individual components.

In most cases replacing the sleeve does the job but in some (maybe 1 in 3 or 1 in 4) the splines on the transfer box are damaged as well and the transfer box needs to be replaced. (£1000 exchange from Volvo, £150-£250 unknown second hand on e-bay). You cannot tell if this is the case until you have removed the transfer box - which requires most of the disassembly.

Also - a failed splined sleeve does not cause any error codes, so not sure what the indie was referring to.

If you search a bit more on here someone has done a good thread with photos.

With regard to parking assist - do you get an error message on the dash about it?

[ts72]

Here you go,

http://www.volvoforums.org.uk/showthread.php?t=254393

Did mine recently and I took photos of the complete service kit plus part no's etc (all within the thread). The service kit I got from Volvo was around £110 last summer.

Fun job mind you

[Maccartw]

Absolute legend, thank you, thank you. How did I miss this thread? Should be in a separate section marked Workshop Guides.

Well there's my weekend filled. Now to blag the local garage for the Enormous Gear Puller. (........title for my next children's book?)

RE: parking sensors, no faults found on the sensors, I have been advised if it is NOT a sensor fault then replace the control unit. £160.00 from volvo, £85 from fleabay. Hmmm.

[owenfackrell]

When we got ours some times when putting it to reverse the sensors would go off continually as though there was some thing in the way. When checking something else in the passenger side boot I found that the control unit was loose and could move around freely. Since fixing back in place I've not had any problems with it so it's worth checking out.

[Maccartw]

Sorry Tarraton to your other question.
Yes, message on the dash, not entirely happy with the display though. I had the binnacle repaired by Cartronix to clear a SRS fault, which they couldn't. They advised me that someone had attempted to repair the binnacle before and left off all the heatsinks. They couldn't clear the fault.
Indy said there were stored fault codes on the system when he used a basic code reader but that VADIS/VADA found no faults on the system. Indy said he was inclined to think VADIS will be the correct one.