S40 2.0d 2010 r-design

[Bob64]

Hi all,
I'm new to this forum and am so impressed with all the help given and shared, maybe someone can help me or advice
My son has had 3 s40s all 2.0d and has turned me into a volvo s40 enthusiast, so I decided
To buy one, s40 2.0d 2010 r design, in beautiful condition for its age it's done 112.000 miles

When I test drove it I took it on a 20 mile drive and heard what I assumed was a wheel bearing noise but couldn't quite make out were it was coming from but was so pleased
With its performance that I quietly made my mind up I would get the bearing fixed

I took it to my local garage for inspection as soon as it went up we noticed the left lower control arm bushes were really worn and the drivers side was not to good but looking
Further seen transmission fluid leaking from drivers side intermediate shaft oil seal,

I had the oil seal replaced but my machanic said he noticed the shaft wouldn't go all the way back into the gearbox, he drove it and heard the wearing noise and checked all bearings and said they were OK, he fears there might have been a gearbox change? But couldn't confirm if it was the right gearbox for the drive shaft, since then it continues to leak after new seal,

Sorry for the long story but I'm in a delema now,
Apparently it's not the wheel bearings making the noise ?
Could the lower control arm cause such a noise like this?
How can I distinguish between wrong gearbox or faulty intermediate shaft

My apologies for going on but I'm so deflated, any help or advice would be so much appreciated
Best wishes
Bob

[Bellini]

Bob, please check your tyres.

My C30 2.0d made a constant humming / droning noise which seemed to be from the rear. I assumed wheel bearings. Something seemed to be causing mild vibration, especially after around town use, too.

My local Volvo specialist confirmed all was well with bearings and driveshafts and pointed instead to the rear tyres and brakes. The front calipers were sticking, so these were fixed and new pads fitted. This was despite a main dealer service 2 months ago.

My local tyre place checked the rear tyres and confirmed they were out of round, so these were replaced.

No more humming / droning.

[Bob64]

Hi friend. Sorry for late reply and thanks for your suggestions. I have had those things checked all ok. But have been all over trying to solve problem droning noise / more so when turning right. But intermittent even driving straight, as I stated my machanic after replacing driver side intermediate shaft oil seal discovered that the shaft wouldn’t go all the way into gearbox. And had been like that since I bought it ( 9/nov). Anyway apparently the shaft is to short to create a proper oil seal hence the leak. However still engages in drive. But will continue to leak until I replace with the right d/shaft.

My son has the same model as I do. So the machanic had both cars up in garage to compare. That’s were he found that my shaft was to small. (Reason for oil seal leak). He took measurements of shaft on my sons car and suggested I get a used shaft with dimensions of my sons car first. Before doing any more repairs ( front o/side control arm as bushes and ball joint worn). As he says that wrong shaft may have done some damage to the diff bearing causing the wearing noise. So that’s were I’m up to. Have to go looking for shaft now that fits the dimensions of my sons intermediate shaft. He fears tho there might have been a gearbox change from different model year or engine size. Can anyone tell me we’re the engine number is on s40 2.0d 2010. R design.
Thanks so much in advance
Bob