The color and the appearance of it having collected in the forward seam suggests a slurry to me. Driving over fresh white paint stripes on a dirt road in the rain lately? Can you gouge out a sample with a veining tool (please excuse the wood carving tool reference) and burn it? The resulting flame c...

Bevel gear install: Bevel Gear went in fine today but I ran out of time and didn't get the propshaft reinstalled. New Bolts.jpg I learned something new regarding the top two 13mm bolts for the BG though: if you maneuver your hand through the exhaust/cat tunnel by the O2 sensor wire, you can easily a...

Update: three days of hard driving and washboard gravel roads and highway driving totalling 1200 kms and all’s well! No vibration, leaks or strange noises. I tried to put the welded sleeve through it’s paces to ensure it wouldn’t fail and it held solid. I feel with this setup that there should be no...

Also buy a new set of bleeder screws and replace all of them.

Pete, there was ORE V70XC for 2002. I know a guy who drives 235/650. "In 2001, to mark their sponsorship of the just renamed Volvo Ocean Race, special Ocean Race editions of the V70 and V70 XC were announced. Released for model year 2002 the cars only came painted in a unique shade of blue. Sil...

Hey Everything is pressed apart and enjoying the cleaning process ultrasonic style :) New bearings for the pinion should arrive this Friday ... With good friends and the right tools everything is possible an quite fun. Last test drive of old bearings and I'm 99% sure this is the bearing sound that I...

Just found the source of the sound, a bad bearing race.

Well I think I definitively determined the problem. I put 12 volts to the pump and no life in either direction. That Dorman pump lasted 6 months. I'll order a new Volvo one today and look forward to another day lying under the car Might as well change the fluid and filter again too.

Thanks Blacklab467 for the update. I have a 2006 BMW 3.0i with xDrive. The BMW xDrive AWD system is much better than Volvo. My 2005 XC90 2.5T AWD stripped the sleeve, so knowing that the Volvo early-design AWD has so many issues (stripped sleeve, angle gear leaking, the rear electronic DEM etc. etc....

Angel gear is now back together
A couple of highlights from my afternoon assembly

RTV should now cure for 24h, so maybe it will find its way back in the car tomorrow.