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Procedures to replace Viscous Coupling

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.
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Procedures to replace Viscous Coupling

Postby bobice » 31 Jan 2010, 02:58

My 2000 V70XC AWD makes some noise due to a bad viscous coupling bearing. Since I might be able to get a used VC from another salvaged V70, I am researching on how to do the work. The attached two files are the instructions from VADIS. According to the instructions, I need some special tools, such as the counterhold (9995743) and the dial gauge (9995971). Are these tools absolutely necessary? If so, where can I get these tools?

Any shortcut or tips on how to replace the VC would be appreciated. The AWD is so nice for the Maryland snow!

Thanks.
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Re: Procedures to replace Viscous Coupling

Postby capecodbuilder » 03 May 2010, 23:12

I am also looking for someone with some experience swapping out viscous couplers. After reading the instructions in vidas I was not going to try, instead drive it as a fwd. I now have 5 awd volvos in my possession. All have something wrong with the awd some bad angle gears some bad viscous cplrs. all great cars.
At least one is to be a donor car and at least one of the others is going to end up a fwd.
Adding to my hell is the fact that there are differences with these parts even within the same model year.
I have 3 v70 xc's a 2000, a 99 and 2 98's. I also have a 99 s70 awd.
I see that nobody answered this post and I'm calling you big dogs out!! :D

I plan on swapping a viscous cplr out and throwing a driveshaft from a 3rd car and just bolting it up. the instuctions have you keeping the bolts in the same holes, using flipping dail gauges and such...too much like brain surgery.
Anyone done this? good results?? bad??

Also how about a lesson on using vadis to find out the different parts and there interchangeability? I ask for the world here I know, but I also know that I am asking the right group of people.
Thanks in advance you crazy volvo-heads!
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Re: Procedures to replace Viscous Coupling

Postby JRL » 04 May 2010, 03:28

Remove propshaft
Unbolt old VC
Remove old one
Replace with new one
Install propshaft
Very simple
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Re: Procedures to replace Viscous Coupling

Postby capecodbuilder » 04 May 2010, 19:14

WOW! now that was a really thoughtful response... yeah, I get how to do it if your a freaking primate. I have no problem in that area. I am an ape.
Heres the rub... I read the instructions for how to do it if your a Volvo dealership making a fortune reinventing the wheel, while being payed by the hour,and it left me (and the original poster) feeling that, perhaps, the knuckle-draggers method (that jrl describes in such poetic detail) will leave me with a vibrating and self-destructive V/C... hardly worth the effort when driving it as a fwd is fine.
So I'll re-word the question... has anyone simply bolted up a V/C from a donor car without following the ridiculously drawn-out process described in the attached vadis pdf? If you have done so, please share your results.
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Re: Procedures to replace Viscous Coupling

Postby steve_v70xc » 10 May 2010, 16:24

Hello capecodbuilder,

I have a '99 V70XC with most likely a bad viscous coupler -- I'm hearing some noise in that area and it's getting louder. My mechanic took a look and said it could be that I need to replace the viscous coupler entirely or just replace the viscous coupler bearing -- the VC was not removed from the car, it was inspected in place on the car. A third potential source of the noise, according to my mechanic, is the rear differential. The inspection has already cost me $115 and to pull the VC off for further inspection will be another $300. Then, if the VC is bad I've heard it will cost around $1300 for the part. After spending $4K on this car in the past year or so (and only driving it 10K miles in that time!) I'm getting pretty tired of the expenses. Which brings me to my question (sorry it took so long!) -- what do you mean by "drive it as a FWD?" Can I just let this go (no repair)? This is way beyond my mechanical abilities/knowledge -- I'd like to keep the car if I can drive it WITHOUT making any repair to the VC -- I don't care if the AWD in non-functional, FWD is fine with me. I just don't want the car to leave me stranded or cause an accident. If this is not an option, I am going to sell this car and move on, the maintenance/repair costs are killing me since I can't do much of the work myself.

Thanks in advance for any and all replies/suggestions!
Steve

P.S. The car has only 116K miles on it! Such a short life considering how many problems I've had with it.
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Re: Procedures to replace Viscous Coupling

Postby bobice » 10 May 2010, 16:59

Based on other threads, I think it is OK to leave the car as is, if you don't mind the noise. That's what I'm doing now.

I plan to take the VC out once the noise is un-bearable. But it's absolutely OK or may be better to remove the VC now and make the car FWD.



steve_v70xc wrote:Hello capecodbuilder,

I have a '99 V70XC with most likely a bad viscous coupler -- I'm hearing some noise in that area and it's getting louder. My mechanic took a look and said it could be that I need to replace the viscous coupler entirely or just replace the viscous coupler bearing -- the VC was not removed from the car, it was inspected in place on the car. A third potential source of the noise, according to my mechanic, is the rear differential. The inspection has already cost me $115 and to pull the VC off for further inspection will be another $300. Then, if the VC is bad I've heard it will cost around $1300 for the part. After spending $4K on this car in the past year or so (and only driving it 10K miles in that time!) I'm getting pretty tired of the expenses. Which brings me to my question (sorry it took so long!) -- what do you mean by "drive it as a FWD?" Can I just let this go (no repair)? This is way beyond my mechanical abilities/knowledge -- I'd like to keep the car if I can drive it WITHOUT making any repair to the VC -- I don't care if the AWD in non-functional, FWD is fine with me. I just don't want the car to leave me stranded or cause an accident. If this is not an option, I am going to sell this car and move on, the maintenance/repair costs are killing me since I can't do much of the work myself.

Thanks in advance for any and all replies/suggestions!
Steve

P.S. The car has only 116K miles on it! Such a short life considering how many problems I've had with it.
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Re: Procedures to replace Viscous Coupling

Postby capecodbuilder » 10 May 2010, 17:02

Hello Steve, Yes you can convert to fwd. All that is ness. is that you take out your drive shaft...and call it macaroni.
I have done this and I'm happy. There are a few threads on this site pertaining to this method of dealing with the troubled awd set-up on these Volvo's. If your rear-end is faulty you might be a good candidate for the next step, a step I'm about to take. I'm not too sure about anyone else talking about this aspect on here but here goes...(also, anyone with an opinion or experience in doing the following please chime-in)
Once you disconnect the drive shaft, you are driving a fwd wagon. The only thing I am not thrilled about is the fact that I am still turning an angle gear and dragging a rear diff around which is a waste of gas/power.
This is esp. a prob if the angle gear or rear diff is faulty/noisy.
As far as I can tell the angle gear is holding a sleeve onto a shaft that comes out of the tranny and perhaps adhering the sleeve to the shaft is all that is ness to remove the a.g. all together...and sell it for a few hundred bux!
As for the rear diff. I am going to remove the axle's from the rear and drain any fluid out of the diff...allowing the rear tires to spin freely and not turn a useless (and in your case noisy)rear diff.
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Re: Procedures to replace Viscous Coupling

Postby JDS60R » 10 May 2010, 19:21

You can remove the rear shafts and then you only have the dead weight of the coupler and differential. This elimates the internal drag.

I'm not sure the diference in gas mileage is worth the effort but if my diff or AOD was going the you could consider it.
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Re: Procedures to replace Viscous Coupling

Postby steve_v70xc » 11 May 2010, 19:07

Thank you all for your helpful replies. I will search this site for the procedure to remove (and not replace!) my driveshaft (same thing as propeller shaft, I assume). As long as the noise is gone and the car is safe I'll be happy. Kind of sad that I haven't had many chances to take advantage of the AWD. It's only been in the show a few times, but when it was, it really handled well. And it's always felt so stable on wet/slick roads. I've assumed that was due to the AWD but maybe it's just the car in general. So solid compared to other cars I've recently owned (Accord, Camry, Sienna).
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Re: Procedures to replace Viscous Coupling

Postby JRL » 11 May 2010, 21:03

You can also remove the VC with the driveshaft.
Since there won't be anything going to the rear diff, it probably will be OK afterwards and to the OP, it really IS that simple;
just unbolt the VC and remove it
(Put the bolts back in (just in case) so the bolt holes won't rust up
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Re: Procedures to replace Viscous Coupling

Postby steve_v70xc » 12 May 2010, 21:01

Thanks JRL!

Any comment on the need for special tools in order to remove the VC? bobice asked about this in an earlier post. All I have are basic tools, nothing specific to Volvo.

Thanks again,
Steve
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Re: Procedures to replace Viscous Coupling

Postby holler1 » 12 May 2010, 23:38

As far as I can tell the angle gear is holding a sleeve onto a shaft that comes out of the tranny and perhaps adhering the sleeve to the shaft is all that is ness to remove the a.g. all together...and sell it for a few hundred bux!

There was a thread on removing the angle gear a year or so ago. I think it was on Volvospeed. I haven't done it but it looked pretty straightforward.
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