AWD Transmission: - XC90 rear subframe change

1tinkerer · Dec 23rd, 2021, 19:51

Hi all,
I am currently pulling what is left of my hair out!! I have to change the rear subframe out as it is rusty am I found a couple of holes in the current one. I knew it was a little rusty, but was not expecting this..

Anyway, I need to remove the haldex and diff, but I cannot take the driveshafts or the prop shaft out... I have removed the bolts on the propshaft and it will not budge. The driveshafts dont want to move either.
Has anyone any tips or advice as to how to do this?

Thanks..

Dancake · Dec 23rd, 2021, 20:38

Have you tried a large deadblow nylon mallet?

1tinkerer · Dec 23rd, 2021, 21:37

I have a large hide mallet that I have been trying for the prop shaft, but it ain't budging.. I have tried pulling it out and tapping at the sides to see if I can loosen the grip, but nothing is moving.
I need the drive-shafts out also, but just cant get a grip to prise them out either..

1tinkerer · Dec 26th, 2021, 13:25

Hi all,
Just to let you know, I got the prop shaft off and the driveshafts out. I found the screw holes on the back of the coupling to drive the joint out of the coupling. Drive shafts weren't too bad either..
New subframe then all back in..

SkipjackUK · Dec 26th, 2021, 18:41

any idea why your rear subframe was so rusted? my 2003 has visible rust as too be expected, never really banged around and checked it.

just wondering if your has had a life near water or the sea?

glad you got it sorted, what year?

1tinkerer · Dec 31st, 2021, 00:15

Hi there,
I reckon that a previous owner had used it for a boat or the like. The Subframe was really bad and has holed in a number of places. The bodywork at the rear has also suffered a little underneath, bit I can hopefully get that cleaned up and sealed/painted before refitting the subframe. It is a 2004. I have a 2005 subframe to replace it is like new in comparison..

SkipjackUK · Dec 31st, 2021, 08:16

Good, we need to preserve these 1st Gen D5's and keep them on the road

well worth doing if everything else is performing nicely. such a lovely SUV

1tinkerer · Dec 31st, 2021, 21:00

Yes indeed, they are nice and generally quite good. I have the replacement subframe stripped and washed for checking, but it seems much much better thank goodness. My heart sank last week when I found a hole or two. Seeing some light now at the end of the tunnel.. I will post some photos when I am able..

Happy New Year everyone..

1tinkerer · Dec 31st, 2021, 21:17

A couple of photos of the donor subframe being removed and the general condition. It is stripped now and I gave it a good wash, so it doesnt look just as crusty..

Dec 23rd, 2021, 19:51	#1
1tinkerer New Member Last Online: Dec 22nd, 2023 20:24 Join Date: Jul 2014 Location: Loughgall	XC90 rear subframe change Hi all, I am currently pulling what is left of my hair out!! I have to change the rear subframe out as it is rusty am I found a couple of holes in the current one. I knew it was a little rusty, but was not expecting this.. Anyway, I need to remove the haldex and diff, but I cannot take the driveshafts or the prop shaft out... I have removed the bolts on the propshaft and it will not budge. The driveshafts dont want to move either. Has anyone any tips or advice as to how to do this? Thanks..

Dec 23rd, 2021, 20:38	#2
Dancake Premier Member Last Online: Today 00:06 Join Date: Apr 2011 Location: Belfast	Have you tried a large deadblow nylon mallet? __________________ 1996 850 T5 - Sold 2003 S40 1.9d - Sold 2004 S60 D5

Dec 26th, 2021, 18:41	#5
SkipjackUK VOC Member Last Online: Mar 10th, 2023 20:29 Join Date: Jul 2013 Location: Leeds & Crewe	any idea why your rear subframe was so rusted? my 2003 has visible rust as too be expected, never really banged around and checked it. just wondering if your has had a life near water or the sea? glad you got it sorted, what year? __________________ 2003 - 1G XC90 D5 Euro3, replaced AWD and gearbox at 140k (April 2022 @196k)

Dec 31st, 2021, 08:16	#7
SkipjackUK VOC Member Last Online: Mar 10th, 2023 20:29 Join Date: Jul 2013 Location: Leeds & Crewe	Good, we need to preserve these 1st Gen D5's and keep them on the road well worth doing if everything else is performing nicely. such a lovely SUV __________________ 2003 - 1G XC90 D5 Euro3, replaced AWD and gearbox at 140k (April 2022 @196k)

Dec 23rd, 2021, 21:37	#3
1tinkerer New Member Last Online: Dec 22nd, 2023 20:24 Join Date: Jul 2014 Location: Loughgall	I have a large hide mallet that I have been trying for the prop shaft, but it ain't budging.. I have tried pulling it out and tapping at the sides to see if I can loosen the grip, but nothing is moving. I need the drive-shafts out also, but just cant get a grip to prise them out either..

Dec 26th, 2021, 13:25	#4
1tinkerer New Member Last Online: Dec 22nd, 2023 20:24 Join Date: Jul 2014 Location: Loughgall	Hi all, Just to let you know, I got the prop shaft off and the driveshafts out. I found the screw holes on the back of the coupling to drive the joint out of the coupling. Drive shafts weren't too bad either.. New subframe then all back in..

Dec 31st, 2021, 00:15	#6
1tinkerer New Member Last Online: Dec 22nd, 2023 20:24 Join Date: Jul 2014 Location: Loughgall	Hi there, I reckon that a previous owner had used it for a boat or the like. The Subframe was really bad and has holed in a number of places. The bodywork at the rear has also suffered a little underneath, bit I can hopefully get that cleaned up and sealed/painted before refitting the subframe. It is a 2004. I have a 2005 subframe to replace it is like new in comparison..

Dec 31st, 2021, 21:00	#8
1tinkerer New Member Last Online: Dec 22nd, 2023 20:24 Join Date: Jul 2014 Location: Loughgall	Yes indeed, they are nice and generally quite good. I have the replacement subframe stripped and washed for checking, but it seems much much better thank goodness. My heart sank last week when I found a hole or two. Seeing some light now at the end of the tunnel.. I will post some photos when I am able.. Happy New Year everyone..

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