AWD Transmission: Can't remove AWD fluid pump - Haldex 4

[drjarmin]

Hello All

I have been getting intermittent AWD error messages and a couple of times the AWD system has failed. I am looking to replace the filter and clean out the pump on the system but I just can't seem to get the pump out. I don't want to put too much pressure on it as it might get damaged. In the Haldex 4 Youtube it seems to come out easily without removing the prop shaft (which I'm not sure how to do).

https://www.youtube.com/watch?v=uZNC06Z7imQ

Is there something I am overlooking / doing wrong?

Thanks!

[S60D5-185]

Yes, watch that video properly. He explains how to do it at 3m. 40 seconds in.

What he did was to remove the pump cover screws first and then remove the two pump retaining hex bolts.

At this stage the cover can be eased forward and past the flange to start with and then pull the pump forward and out.

He didn't film that bit but fully explains what he did at 5m. 30 seconds.

It's all in there including a tiny modification to the cover to assist with future removal if you follow it.

I have Haldex 3 on my XC90 and that requires the prop to be removed at the rear.

Haldex 4 on yours is much easier to work with and that procedure in the video works well because I've done it on a Haldex 4 equipped 90




UPDATE.

Looking at your photo your car may have the vibration damper flange fitted and that is a bigger flange that normal.

Difficult to tell from the angle of on your photo but if you don't have the same clearance as that on the video, you may well have to drop the prop at the rear.

Post another photo showing clearance. My XC90 has the same flange as in the video but is still Haldex 3

[drjarmin]

Thanks, yes I've been following the video religiously. Unfortunately he moved the camera. I just can't get the cover not to snag on the prop and worried I'm 'bending' the motor inside.

Will try again a bit later. Looks so easy in the Youtube

[S60D5-185]

Originally Posted by drjarmin

Thanks, yes I've been following the video religiously. Unfortunately he moved the camera. I just can't get the cover not to snag on the prop and worried I'm 'bending' the motor inside.

Will try again a bit later. Looks so easy in the Youtube

Please post another photo as I'm certain you have the larger flange fitted on the propshaft and if so I doubt if it will clear even with the pump cover loose.

Don't force anything .👍

See this thread. I think that you have the larger flange that this guy subsequently fitted. If so , I doubt there will not be enough room to remove pump easily

https://www.volvoforums.org.uk/showt...ghlight=damper

[drjarmin]

Gave it a big yank and pulled the prop away with a screwdriver and it came out.

The worrying thing is I think I've bent the winding. It looks a fraction off centre. Is this recoverable? Been a disastrous project so far

[S60D5-185]

Originally Posted by drjarmin

Gave it a big yank and pulled the prop away with a screwdriver and it came out.

The worrying thing is I think I've bent the winding. It looks a fraction off centre. Is this recoverable? Been a disastrous project so far

No idea to be honest but if you GENTLY try to ease it straight, that round item at the bottom is the carrier bearing and that needs to be able to sit in the bottom of the cover.

Try to get it straight and assembled and test it using 12v direct onto the pins on the pump plug before putting it back on the haldex unit.

From memory when looking at the pins 12v goes to left and negative to right. Check though.

Good luck. I had to replace the pump on my Haldex 3 a little while ago and it was over £200

[drjarmin]

Thanks. Tried to align it but I think I'm doing more harm than good and a new pump is the way forward unfortunately.

If I put the car together but don't plug in the electrical connectors to the Haldex will I still be able to drive the car (albeit in permanent 2WD) until the new pump arrives?

[S60D5-185]

Originally Posted by drjarmin

Thanks. Tried to align it but I think I'm doing more harm than good and a new pump is the way forward unfortunately.

If I put the car together but don't plug in the electrical connectors to the Haldex will I still be able to drive the car (albeit in permanent 2WD) until the new pump arrives?

I don't see why not.

I base that comment on the fact that many people are blissfully driving around with a non working pump unaware that they are in 2wd only as no error messages appear.

At the end of the day though, it's your call and I did say " Don't force anything"

[drjarmin]

Thanks.

I cant even get the old pump back in at the moment 😭.

How hard is it to get the prop shaft out of the way?

[S60D5-185]

You need to remove the 6 hex bolts that hold the prop CV joint into the flange.

You then need to move the prop out of the flange and once done you need to remove ( preferably with an impact gun ) the nut holding the flange onto the Haldex input shaft.

Once done pull the flange off the shaft which will allow uninterrupted access to the pump housing.