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2005 XC90 Propshaft Removal - Help!

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Old Sep 30th, 2018, 17:25   #1
RGoulden
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Default 2005 XC90 Propshaft Removal - Help!

Hello,

I would be really grateful for any advice in trying to remove the propshaft from the angle transfer box - it is stuck.

I am trying to replace the splined shaft between the gearbox and transfer angle drive. So far reasonably straight forward but have spent half a day trying to get the remove the propshaft.

I have removed the 6 hexagon bolts and followed all of the steps in the various posts and as per the Haynes manual but I just cannot get the propshaft to separate from the coupling.

Does the propshaft joint sit inside the coupling i.e. in a cup sort or arrangement? Or is there some sort of locating pin?

From all of the posts and information I have read, it sounds like it should almost fall off/out. As space is quite tight I cannot even see how you can drift it apart or use any other tools to separate the joint.

Any advice would be much appreciated. I really don't want to give up and put it all back together to then have to pay the stealership or an indi a fivetune (a bit more than a fortune) to fix!

Many thanks

Rob
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Old Sep 30th, 2018, 19:59   #2
osullivant
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From memory it is best to take off a cross member that sits under it. Also the exhaust from the dpf back. It really is an awful job and I destroyed mine the first time. Drop the middle bearing will give some space. Take off all you can because you will need the space putting things back.... mine is a 185 with the improved bearing but I needed to do the turbo...
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Old Sep 30th, 2018, 23:54   #3
Tannaton
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I would try and drive a chisel between the mating surfaces, once the bolts are out they usually fall off.

Contrary to the Haynes manual - there is no need to mark the propshaft flanges and the transfer box/diff. it can go back anyway that fits...
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Old Oct 19th, 2018, 09:49   #4
mazda1109
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did mine last week to remove the angle box ,,
remove the front brace plate 4 bolts
remove all bolts from front prop shaft
remove middle prop support and heat shield tin clips
undo exhaust rear bushes and lower down as much as possible
middle prop support can now be wiggle out
put car in neutral if auto
lower center part of prop and wiggle and twist it it will come away from front joint you can tap front joint with wooden mallet but not to hard took about half hr to remove
hope this helps
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Old Oct 20th, 2018, 22:19   #5
owenfackrell
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Quote:
Originally Posted by mazda1109 View Post
did mine last week to remove the angle box ,,
remove the front brace plate 4 bolts
remove all bolts from front prop shaft
remove middle prop support and heat shield tin clips
undo exhaust rear bushes and lower down as much as possible
middle prop support can now be wiggle out
put car in neutral if auto
lower center part of prop and wiggle and twist it it will come away from front joint you can tap front joint with wooden mallet but not to hard took about half hr to remove
hope this helps
This. I left the rear coupling done up when I did mine.
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