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2003 2.5T gearbox oil leak between transmission and angle gear.

A mid-size luxury crossover SUV, the Volvo XC90 made its debut in 2002 at the Detroit Motor Show. Recognized for its safety, practicality, and comfort, the XC90 is a popular vehicle around the world. The XC90 proved to be very popular, and very good for Volvo's sales numbers, since its introduction in model year 2003 (North America). P2 platform.
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Dragoz001
Posts: 19
Joined: 9 August 2015
Year and Model: Xc90 2004
Location: Lyon, France

2003 2.5T gearbox oil leak between transmission and angle gear.

Post by Dragoz001 »

My gearbox is leaking oil. Its coming from between the tranny and the angle gear.
The angle gear itself is almost new (PO had it replaced).
I suspect the output drive shaft seal and would like to replace it.
Does anyone have experience with this job?
Is it possible to access it by "just" pulling the angle gear to the right?
Are there other seals to replace?
I'm also wondering why some people need to replace the sleeve itself.
Many thanks in advance for your help!

Dragoz001
Posts: 19
Joined: 9 August 2015
Year and Model: Xc90 2004
Location: Lyon, France

Post by Dragoz001 »

Hi,
Here's a follow-up in case someone with the same issue gets here.
Today I removed the angle gear and discovered that the seal sitting inside the sleeve behind the C clip (ref 8636195) was installed crooked.
The lip was partly outside of the inner sleeve.
It's not surprising that I got a big leak as soon as the oil level was reaching that seal.
I personally find that it's a bad design that many seals are not easy to install on these cars just because they don't sit against a shoulder. In this case even a Volvo workshop had a problem.

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Blacklab467
Posts: 1107
Joined: 9 August 2016
Year and Model: 2007 xc 70
Location: Calgary, AB
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Post by Blacklab467 »

You can replace it in situ, no need to remove the collar sleeve. You will probably not be able to get the sleeve off anyway without destroying it. That seal is about $60, make sure you don't buy an aftermarket part for this...........bon chance!
2003 XC 70 (sold)
2007 XC 70, 1970 Dodge Charger R/T.

poto993
Posts: 5
Joined: 7 August 2025
Year and Model: volvo 2020
Location: pennsylvania

Post by poto993 »

i love that aswell.

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