Undisputed Volvo DIY wizard cn90 hits one out of the park, and over the next park, with this outstanding DIY for XC90s. He shows how to change the auto transmission fluid (ATF), angle gear fluid, AOC filter, and AOC fluid and Rear Diff fluid. Yea, goosebumps here too.
This collection of tasks will take a good portion of the “consumables” on an 2.5 Turbo XC90 into the Good For Another 100k Miles Zone™.
INTRO – 2005 Volvo XC90 Driveline Fluid & Refurbish DIY
My newly acquired 2005 XC90 2.5T with 82K miles, it is the usual story: P.O. owns it until now, skipping a few services because of dealer service costs. Now it is my job to bring it up-to-date…
Today is July the 4th, so I went all out war on all fluids replacement…lol!
– ATF is Mobil 3309, case of 12 for ~ $70 on Amazon
– I have been using Redline 75W90 for a long time in my BMW Rear Diff without any issues. It is a very good fluid. This is why I use this in the XC90 Angle Gear (which is basically similar to a diff) and Rear Diff.
– Angle Gear: I removed about 600 mL, you can use Volvo oil (see chart), I used Redline 75W90 oil.
– AOC system: I removed about 500 mL, new PN for oil is 31325136, Volvo sells this for $18/L.
– Rear Diff: I removed about 650 mL, you can use Volvo oil (see chart), I used Redline 75W90 oil.
– Trans Cooler Green Clips: 9485149 ($7/each), qty = 2. These clips break often during removal, so best is to replace them before you get stranded!
– Trans Cooler O-rings: 988840 ($4/each), qty = 4.
– The AOC Filter PN 30787687 ($20): no need to drop exhaust/driveshaft for this job: but your best bet is to buy or make a small ratcheting wrench with 4-mm hex head that can fit in that tight space (see photo). The space is about 32mm, yes it is tight! All stores were closed and I didn’t know where to buy the ratcheting wrench with 4-mm hex head, therefore I improvised with drift + hammer, worked well, read on.
– 24-mm wrench
– 13-mm socket with swivel, Iron Pipe for added leverage
– Long Funnel ($4 at local autoparts store)
– The Oil Suction Gun is fine for filling up fluids but it is not very good at sucking old fluid out. So I used a 60-cc syringe and the stiff Volvo vacuum line I have lying round the garage. It is slow with the syringe but for something I do once every 8-10 years, this is fine. You can also use oil evacuation tool (Pella etc.).
– I re-used all crush washers, just make sure they go back in the same orientation. The little indentation (created by tightening the bolt) on the washer faces the bolt.
– All 3 systems (Angle Gear, AOC, Rear Diff) do NOT have drain plugs. They only have fill plugs (what a dumb design!). All are 13-mm bolts. Do one system at a time to avoid mixing up fluids!