2003 XC90 Noise when driving on driver side

[cocoli2007]

Hi,

My 2003 XC90 (~120k miles) has noise on front driver side brake area when driving, it is not smoothly driving, always feel something is sticking.

At the beginning this month, I had heavy driving for 400 miles. Then there is big noise and driver side brake pad had only 10% left. Mechanic changed calipers ( rebuild) and brake pads on both sides, not change rotors.

Brake is ok now, but still has noise on driver side (not loudly likes before) and I feel driving is not smoothly.

Mechanic said caliper does not fully released and released speed is very slowly. He checked wheel bearing and brake lines, they are ok. I checked YouTube, my car noise is liking bad wheel bearing noise.

I brought my car to Goodyear, Goodyear found passenger side control arm worn out and suggested changed it.

Now I am confused — right side bad control arm can cause noise on left side???

Thanks for reading my post.

[JADXC]

Hi
It probably is your bearing if the brakes caliper is ok. try to drive slalom(like F1 cars worming up the tires) and hear if there is any noise diference when put and release the weight on that side of the car.

[cocoli2007]

Originally Posted by JADXC

Hi
It probably is your bearing if the brakes caliper is ok. try to drive slalom(like F1 cars worming up the tires) and hear if there is any noise diference when put and release the weight on that side of the car.

Thanks.

It is very weird. These two days, there is another big noise comes from angle gear area (next to transmission), this noise is different from noise I mentioned on original post. That time, I can not hear noise when I sat at passage seat.

Now mechanical said he was unable to determine it is chain drive and/or angle drive issue. And labor is 10 hours.

I searched website, I can not find chain drive, what is it?

[Kev0607]

Originally Posted by cocoli2007

Hi,

My 2003 XC90 (~120k miles) has noise on front driver side brake area when driving, it is not smoothly driving, always feel something is sticking.

At the beginning this month, I had heavy driving for 400 miles. Then there is big noise and driver side brake pad had only 10% left. Mechanic changed calipers ( rebuild) and brake pads on both sides, not change rotors.

Brake is ok now, but still has noise on driver side (not loudly likes before) and I feel driving is not smoothly.

Mechanic said caliper does not fully released and released speed is very slowly. He checked wheel bearing and brake lines, they are ok. I checked YouTube, my car noise is liking bad wheel bearing noise.

I brought my car to Goodyear, Goodyear found passenger side control arm worn out and suggested changed it.

Now I am confused — right side bad control arm can cause noise on left side???

Thanks for reading my post.

A worn control arm is a separate issue. That won’t cause the noise or issue you are describing.

So has the mechanic rebuilt the caliper, tested it again and says its releasing slowly after the rebuild? (Anotherwords, what he has done hasn’t worked?). Or do you mean he rebuilt the caliper because it was sticking?

I think you may still have a brake caliper problem. A wheel bearing makes a thumping/whirring sound at speed, not “sticking”. Or, maybe your brake discs might be in poor condition and may have debris on them making the car feel like something is dragging or sticking. If pads were worn down to 10%, I don’t know why he reused those old brake discs. If the caliper was sticking, its likely it damaged the brake disc.

Check calipers and brake discs. You need to find a new mechanic.

[cocoli2007]

Originally Posted by Kev0607

A worn control arm is a separate issue. That won’t cause the noise or issue you are describing.

So has the mechanic rebuilt the caliper, tested it again and says its releasing slowly after the rebuild? (Anotherwords, what he has done hasn’t worked?). Or do you mean he rebuilt the caliper because it was sticking?

I think you may still have a brake caliper problem. A wheel bearing makes a thumping/whirring sound at speed, not “sticking”. Or, maybe your brake discs might be in poor condition and may have debris on them making the car feel like something is dragging or sticking. If pads were worn down to 10%, I don’t know why he reused those old brake discs. If the caliper was sticking, its likely it damaged the brake disc.

Check calipers and brake discs. You need to find a new mechanic.

I purchased rebuild calipers from eeuroparts.com.

Only one mechanic who replaced calipers and brake pad thought it is caliper problem. Other mechanics say no issue with caliper and wheel bearings.

Yesterday, one mechanic lifted car and gave it gas, then found noise comes from angle gear area. He disconnected drive shaft, car is running at FWD, noise is still there. So it is angle gear and/or chain drive issue, need to replace it, but it is too expensive for this old car.

[cocoli2007]

Originally Posted by cocoli2007

I purchased rebuild calipers from eeuroparts.com.

Only one mechanic who replaced calipers and brake pad thought it is caliper problem. Other mechanics say no issue with caliper and wheel bearings.

Yesterday, one mechanic lifted car and gave it gas, then found noise comes from angle gear area. He disconnected drive shaft, car is running at FWD, noise is still there. So it is angle gear and/or chain drive issue, need to replace it, but it is too expensive for this old car.

I did research online, it looks like no new or rebuild angle gear part selling on market and dealers. Only way is getting used from junkyard or eBay, they are pulled out from high mileages Volvo, maybe will be broken soon after 1-2 years.

How did you figure out bad angle gear issue?

Is it still safe to drive this card?

Thanks.

[Kev0607]

Originally Posted by cocoli2007

I did research online, it looks like no new or rebuild angle gear part selling on market and dealers. Only way is getting used from junkyard or eBay, they are pulled out from high mileages Volvo, maybe will be broken soon after 1-2 years.

How did you figure out bad angle gear issue?

Is it still safe to drive this card?

Thanks.

New would cost you a fortune (not worth it). You could buy used, but there's a chance that it may be fine for a long time or it may not last long... that's the problem with used parts.

Do you really need all-wheel-drive? The car can be driven front wheel drive only, but you'll just have to get used to the noise it makes and live with it. If the mechanic disconnected the drive shaft and it still makes noise, then its likely the angle gear that's the issue.

The car can be driven as is front wheel drive only, with the noise. Is it safe? Doing city driving, you'll be okay. If you live in an area with lots of hills and bad terrain, then just having front-wheel-drive may be a problem.

If you really need all-wheel-drive, then you have no option other than fit a used part or look at buying another car. If you don't want to do that, then you may need to live with the noise and drive it as is.

[cocoli2007]

Originally Posted by Kev0607

New would cost you a fortune (not worth it). You could buy used, but there's a chance that it may be fine for a long time or it may not last long... that's the problem with used parts.

Do you really need all-wheel-drive? The car can be driven front wheel drive only, but you'll just have to get used to the noise it makes and live with it. If the mechanic disconnected the drive shaft and it still makes noise, then its likely the angle gear that's the issue.

The car can be driven as is front wheel drive only, with the noise. Is it safe? Doing city driving, you'll be okay. If you live in an area with lots of hills and bad terrain, then just having front-wheel-drive may be a problem.

If you really need all-wheel-drive, then you have no option other than fit a used part or look at buying another car. If you don't want to do that, then you may need to live with the noise and drive it as is.

Thanks for your reply.

I really do not need AWD, but the noise is very loudly and terribly. When I drive it, I feel it maybe stop working anytime.

I read a post, it is said when dealer did angel gear rebuild, they only changed collar sleeve, is it true? I see FCP sell new collar sleeve.

[Kev0607]

Originally Posted by cocoli2007

Thanks for your reply.

I really do not need AWD, but the noise is very loudly and terribly. When I drive it, I feel it maybe stop working anytime.

I read a post, it is said when dealer did angel gear rebuild, they only changed collar sleeve, is it true? I see FCP sell new collar sleeve.

The collar sleeve could be bad, but the angle gear needs to be properly diagnosed and stripped down to see what the problem is. Don't buy any parts until you know exactly what's wrong (if you do plan on fixing it).

[Parknest]

I had a problem with the bevel gear. The bearing for the propshaft had collapsed. The propshaft was fine, I found a used replacement bevel gear on eBay for £200 delivered. Once I'd changed it out it was fine.