AWD Transmission: - How to remove this flange!??

drjarmin · Apr 30th, 2020, 06:09

Been trying to get this flange off the spline from the rear AWD for an hour and really can't budge it. I'm worried if I start giving it a wallop I might damage something I shouldn't.

I have removed the bolt holding it on.

Help!!

S60D5-185 · Apr 30th, 2020, 07:05

First off, has it moved forward at all, I can see that the pump is out.

If it has moved forward a bit, will the new pump slide back in with the flange where it is? If so do that .

The flange is not held on by anything further now so if the pump still can't be fitted with the flange in situ, try using a good piece of timber on the back of it and give the wood a couple of good taps with a heavy hammer. Then turn the flange 180 degress and keep tapping and repeating. Don't hit the flange directly with the hammer.

It might be an idea if you try this to just put the flange nut on just one turn by hand to stop the flange flying off if it suddenly loosens.

As I said, if it has moved forward at all and the new pump will now go in, just do that and then there is no risk to the flange seal being disturbed.

Nothing is holding the flange in situ other than the fact it has been on there since new. It will move!👍

IainG · Apr 30th, 2020, 07:36

Hi
If you are worried about damage,looks like there are tapped holes in the flange.
If you have the facilities just fabricate a puller. Round plate with holes to line up with the tapped holes. Centre hole with a nut welded to it.
Bolt plate to tapped holes. Use a bolt in the centre to press on shaft to allow the flange to come off.
I am sure something could be made easily.
Iain

ShakTak · Apr 30th, 2020, 07:50

They tap off easily. You just need to hit it as close to the centre at the back with something long enough to gain access (socket extension, etc) and a hammer, not the edge, as that has a rubber ring and soaks up the impact.

S60D5-185 · Apr 30th, 2020, 09:14

Quote:

Originally Posted by IainG

Hi
If you are worried about damage,looks like there are tapped holes in the flange.
If you have the facilities just fabricate a puller. Round plate with holes to line up with the tapped holes. Centre hole with a nut welded to it.
Bolt plate to tapped holes. Use a bolt in the centre to press on shaft to allow the flange to come off.
I am sure something could be made easily.
Iain

No puller needed Ian, they just tap off.👍

drjarmin · May 4th, 2020, 04:34

Thanks everyone for your help. Went back and got the flange off in minutes. I guess I wasn't hitting it hard enough before.

The suggestion to reinstall the nut before giving it a bash was a good one!

Sorry for so many questions on this job. Turned out way bigger than I initially expected - looked so easy on YouTube! Lot's of lessons learned and I couldn't have done this without all your help.

I did get two Service Errors once everything was reconnected but cleared them and all seems to be working well.

S60D5-185 - Double thank you for your coaching and patience! I know this is a community forum and people are here to help but would like to offer a donation to a local charity of your choice as a token of thanks. You saved my bacon on this one!

S60D5-185 · May 4th, 2020, 07:16

Good man and well done for sticking with it.

The sense of satisfaction for you doing this has to be high and also, it will give you confidence to tackle future jobs.

No need for any donations to charity, I was happy to help.

One other thing that you did and some others needing help have not, is to be pleasant, say thanks and perhaps most importantly update the thread when you have completed the job.

It's a massively knowledgeable Forum and I have been helped out many times.👍

Apr 30th, 2020, 07:05	#2
S60D5-185 Me ? Surely Not! Last Online: Apr 25th, 2024 19:48 Join Date: Jul 2010 Location: 2007 Volvo XC90 D5 Geartronic. South of Hadrians Wall.	First off, has it moved forward at all, I can see that the pump is out. If it has moved forward a bit, will the new pump slide back in with the flange where it is? If so do that . The flange is not held on by anything further now so if the pump still can't be fitted with the flange in situ, try using a good piece of timber on the back of it and give the wood a couple of good taps with a heavy hammer. Then turn the flange 180 degress and keep tapping and repeating. Don't hit the flange directly with the hammer. It might be an idea if you try this to just put the flange nut on just one turn by hand to stop the flange flying off if it suddenly loosens. As I said, if it has moved forward at all and the new pump will now go in, just do that and then there is no risk to the flange seal being disturbed. Nothing is holding the flange in situ other than the fact it has been on there since new. It will move!👍 __________________ “Do the right thing. It will gratify some people and astonish the rest.” – Mark Twain 😊 2007 Volvo XC90 D5 SE Geartronic Last edited by S60D5-185; Apr 30th, 2020 at 07:09.

Apr 30th, 2020, 07:50	#4
ShakTak XC90 Last Online: Yesterday 18:28 Join Date: Jun 2013 Location: North Yorkshire	They tap off easily. You just need to hit it as close to the centre at the back with something long enough to gain access (socket extension, etc) and a hammer, not the edge, as that has a rubber ring and soaks up the impact. __________________ XC90 Last edited by ShakTak; Apr 30th, 2020 at 07:56.

May 4th, 2020, 07:16	#7
S60D5-185 Me ? Surely Not! Last Online: Apr 25th, 2024 19:48 Join Date: Jul 2010 Location: 2007 Volvo XC90 D5 Geartronic. South of Hadrians Wall.	Good man and well done for sticking with it. The sense of satisfaction for you doing this has to be high and also, it will give you confidence to tackle future jobs. No need for any donations to charity, I was happy to help. One other thing that you did and some others needing help have not, is to be pleasant, say thanks and perhaps most importantly update the thread when you have completed the job. It's a massively knowledgeable Forum and I have been helped out many times.👍 __________________ “Do the right thing. It will gratify some people and astonish the rest.” – Mark Twain 😊 2007 Volvo XC90 D5 SE Geartronic Last edited by S60D5-185; May 4th, 2020 at 07:19.

Apr 30th, 2020, 07:36	#3
IainG Premier Member Last Online: Today 05:30 Join Date: Apr 2013 Location: Plymouth	Hi If you are worried about damage,looks like there are tapped holes in the flange. If you have the facilities just fabricate a puller. Round plate with holes to line up with the tapped holes. Centre hole with a nut welded to it. Bolt plate to tapped holes. Use a bolt in the centre to press on shaft to allow the flange to come off. I am sure something could be made easily. Iain

May 4th, 2020, 04:34	#6
drjarmin Member Last Online: Mar 10th, 2024 12:56 Join Date: Aug 2012 Location: Hong Kong	Thanks everyone for your help. Went back and got the flange off in minutes. I guess I wasn't hitting it hard enough before. The suggestion to reinstall the nut before giving it a bash was a good one! Sorry for so many questions on this job. Turned out way bigger than I initially expected - looked so easy on YouTube! Lot's of lessons learned and I couldn't have done this without all your help. I did get two Service Errors once everything was reconnected but cleared them and all seems to be working well. S60D5-185 - Double thank you for your coaching and patience! I know this is a community forum and people are here to help but would like to offer a donation to a local charity of your choice as a token of thanks. You saved my bacon on this one!

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