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DIY Servicing. 2003 model

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Old Jul 28th, 2017, 21:38   #1
Father Ted
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Default DIY Servicing. 2003 model

So, I've just bought my first XC90.
It's a 2003 diesel auto.

I think it will be serviced before I pick it up, but in the medium term I want to be doing the stuff which isn't usually looked at.
First thing is ATF. I don't bother with the full 16 litres flush out. I dump the sump (usually about 4 litres) and replace that, then every year I suck out 2L and put 2L fresh in. That way there isn't a shock to the box.
Engine oil and filters, all go without saying.

But: AWD system fluids. What should I be looking at? Car has 97000 miles on it. I would be looking to swap these out soon as they have probably never been done. Presumably hypoid in rear diff? Is transfer box normal gear oil too or is it closer to ATF?

This might all be in the manual, but I haven't got that yet.

Also, I have read that there is a specific procedure for removing / refitting battery. What is this?
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Old Aug 20th, 2017, 20:02   #2
Father Ted
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Bump.

Has nobody ever changed out the transfer box oil or Haldex unit?

I've found a great video for Haldex unit, but nothing so far on transfer box.
The manual doesn't help as, in fairness, most owners wouldn't be looking at doing this sort of job.
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Old Aug 20th, 2017, 21:47   #3
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With regard to the autobox I would suggest at 97k I would do two or three sump drops (4-5L) about 200-300 miles apart, especially if the fluid is black, it should be fully changed.

As regards the rest of the drivetrain, you have the transfer box which is a sod as there is no drain plug (you use a syringe) - then the Haldex unit and then the rear diff.

The transfer box and rear diff aren't particularly sophisticated or fragile so the oil does usually run the life of the car but there is no harm in changing it (I have done on mine).

The Haldex unit - like the gearbox - is one area where Volvo seem to take a more sanguine view to oil changes that other manufacturers who fit the same units. I would change it asap, and the filter.

With regard to removing/refitting the battery - for some reason a lot gets talked about this but it's really simple. Unscrew the terminals and lift it out.... with two recommendations:

- It is "best practice" to remove the -ve terminal from the battery first and connect it last when refitting. The only reason for this is if you catch your spanner on the bodywork whilst working on the positive terminal, you wont cause a short circuit as the -ve will be off.

- Volvo recommend reconnecting the battery whilst the ignition key is at Pos II (ignition on). The only reason for doing this is that when the airbag system is first re-energised after working on the cars electrical system - you are not leaning over the steering wheel.... it's nothing to do with power surges or damaging ECU's.

Hope this helps.
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Old Aug 20th, 2017, 22:16   #4
Father Ted
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Thanks.
I'd read the bit about the battery. The warnings I'd seen seem a bit over the top!

The transfer box: I might buy another 12v pump from Lidl. I already have one for the ATF but I won't use it for a different oil type.
Is the fill plug obvious?

I have a Haynes manual on order, so, hopefully, there will be pictures showing drain / fill plugs.

Haldex unit concerns me, but once I've had a look I'm sure it can't be so difficult.
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