Rear Differential Noise

Moose Test · Apr 25th, 2018, 17:48

For some time my 07 V8 XC90 has been giving what I'd consider (based on the other D5 '90 I currently own) excessive noise from the rear when traveling at speed. I don't particularly notice anything until traveling over 50 MPH, when it suddenly becomes pronounced (and annoying). I'd considered the possibilities of worn and/or failing diff, shaft(s) or wheel bearings.

So today I took it into a local main dealer for a road test and diagnostics - and it's the rear diff. Oil levels are ok but it was the source of the noise, when run up on their ramp.

I'm looking for some advice, since whilst I've yet to hear back from them with regards to costs, I highly doubt that this isn't going to be extremely painful in the wallet.

Do I just ignore it and learn to live with it? Or will it fall down and go boom at the worst possible moment, in a shower of cogs and shrapnel (as one user reported)?

The thought had occured to me that the 05 MY D5 (163PS) I have might be forced into donating its diff unit - is this viable?

TIA

xc90fubar · Apr 25th, 2018, 18:24

Proceed with caution.

My diff ran dry after a 1500 mile round trip to the Alps - there was obviously a leak as there was a fine mist of oil on the rear of the car but nothing major and I assumed (in liaison with Volvo) it could wait to get checked out properly.

It let go in a big way at 130kph (cough) on the french auto-route, split in half like an apple being sliced by a bread knife. Took out the prop with it and damaged the haldex. The repair estimate was around £10K, car out of warranty - hence the vehicle having been front wheel drive ever since (100,000 miles later still going strong).

Moose Test · Apr 26th, 2018, 12:23

The quote from the main dealer came in a few minutes ago - £3k inc. VAT !

Based on the feedback above and the fact that now I know it's there, it will bug me whilst I continue to own the vehicle, I am on the verge of simply paying up.

However before I do, may I ask if anyone has anything, positive or negative, to say about reconditioning services? A quick google search yesterday revealed an outfit not far from me who advertise removal, refurbishment and re-installation within one business day, at around the £1K mark.

Is that a plausible / wise option? Or just putting expensive lipstick on a pig?

john langrick · Apr 26th, 2018, 15:57

Hi, not sure if this is an option, but is the rear diff different from a lower powered xc90 of same year? I understand you may have an uprated drive train so perhaps not easy.

From what I read, this is not a common failure and if the component is same as on a regular power xc90, it may be worth considering a unit from a dismantler.

I see some on eBay at the moment from late 'vintage' xc90 for < £300, could this be worth a try?

Just a thought.

S60D5-185 · Apr 26th, 2018, 16:33

I would be looking at a second hand option and would not even consider spending £3k on sorting this issue out.

Apr 25th, 2018, 17:48	#1
Moose Test Master Member Last Online: Today 21:10 Join Date: Sep 2017 Location: Norfolk	Rear Differential Noise For some time my 07 V8 XC90 has been giving what I'd consider (based on the other D5 '90 I currently own) excessive noise from the rear when traveling at speed. I don't particularly notice anything until traveling over 50 MPH, when it suddenly becomes pronounced (and annoying). I'd considered the possibilities of worn and/or failing diff, shaft(s) or wheel bearings. So today I took it into a local main dealer for a road test and diagnostics - and it's the rear diff. Oil levels are ok but it was the source of the noise, when run up on their ramp. I'm looking for some advice, since whilst I've yet to hear back from them with regards to costs, I highly doubt that this isn't going to be extremely painful in the wallet. Do I just ignore it and learn to live with it? Or will it fall down and go boom at the worst possible moment, in a shower of cogs and shrapnel (as one user reported)? The thought had occured to me that the 05 MY D5 (163PS) I have might be forced into donating its diff unit - is this viable? TIA

Apr 26th, 2018, 16:33	#5
S60D5-185 Me ? Surely Not! Last Online: Today 19:48 Join Date: Jul 2010 Location: 2007 Volvo XC90 D5 Geartronic. South of Hadrians Wall.	I would be looking at a second hand option and would not even consider spending £3k on sorting this issue out. __________________ “Do the right thing. It will gratify some people and astonish the rest.” – Mark Twain 😊 2007 Volvo XC90 D5 SE Geartronic

Apr 25th, 2018, 18:24	#2
xc90fubar Junior Member Last Online: May 27th, 2023 08:33 Join Date: Feb 2011 Location: london	Proceed with caution. My diff ran dry after a 1500 mile round trip to the Alps - there was obviously a leak as there was a fine mist of oil on the rear of the car but nothing major and I assumed (in liaison with Volvo) it could wait to get checked out properly. It let go in a big way at 130kph (cough) on the french auto-route, split in half like an apple being sliced by a bread knife. Took out the prop with it and damaged the haldex. The repair estimate was around £10K, car out of warranty - hence the vehicle having been front wheel drive ever since (100,000 miles later still going strong).

Apr 26th, 2018, 12:23	#3
Moose Test Master Member Last Online: Today 21:10 Join Date: Sep 2017 Location: Norfolk	The quote from the main dealer came in a few minutes ago - £3k inc. VAT ! Based on the feedback above and the fact that now I know it's there, it will bug me whilst I continue to own the vehicle, I am on the verge of simply paying up. However before I do, may I ask if anyone has anything, positive or negative, to say about reconditioning services? A quick google search yesterday revealed an outfit not far from me who advertise removal, refurbishment and re-installation within one business day, at around the £1K mark. Is that a plausible / wise option? Or just putting expensive lipstick on a pig?

Apr 26th, 2018, 15:57	#4
john langrick Master Member Last Online: Today 20:44 Join Date: Dec 2016 Location: Southend on sea	Hi, not sure if this is an option, but is the rear diff different from a lower powered xc90 of same year? I understand you may have an uprated drive train so perhaps not easy. From what I read, this is not a common failure and if the component is same as on a regular power xc90, it may be worth considering a unit from a dismantler. I see some on eBay at the moment from late 'vintage' xc90 for < £300, could this be worth a try? Just a thought.

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