2003-2006 XC90 T6 advice needed

[scot850]

Still looking into options of what I should buy on an XC90. Ideally would like a low km 03-06 2.5T AWD, but they are rarer here than rocking horse droppings. Already found out I could live with a 3.2 i6 if I can't find what I want, but I'm wondering what are the issues with the 03-06 T6 XC90 that are different to the 2.5T. I know the S80 T6 has issues with head gaskets and auto trans, as well as the speedo cluster. There have been a couple of low km 04 T6's for sale locally with less than 100k miles on them, but interestingly, both have had trans rebuilt recently. Is this normal? If so when do the auto trans improve if at all?

My gut says run a mile where the T6 is concerned, is that a fair assessment?

Thanks,

Neil.

[SuperHerman]

I have a 2004 XC90 T6 - tranny went out at 84k - now at about 130k. About 5 years and going strong. Dealer replaced tranny and related at Volvo's cost.

Car has had no engine issues, save for a few sensors here and there. Nothing I would complain about on any brand of car. In other words normal.

I don't find anything wrong with the vehicle. It is rough on tires, make sure they have a high load rating, and likes suspension parts every few years.

If you look at a T6 that has had tranny issues you need to see the service papers. From what I understand, and I may be wrong, but Volvo changes many related parts when they service the tranny failure for radiator/cooler/failure cross contamination. Basically anything with coolant and tranny fluid gets changed out. This is because of the cross contamination issues. Some state that flushing various parts very well is just as effective as complete replacement. I would assume that a thorough cleaning should suffice, but I have never done it.

So with that said - if the tranny comes with a warranty and you are happy with the paperwork and how the repair was handled I would not be afraid of the T6.

Caveat - you need to know what was the cause and/or nature of the transmission repair. Not all T6 transmission failures are the same. Some could be just the transmission, unrelated to coolant/transmission fluid mixing. Meaning - you may still have a coolant/transmission failure if the radiator was not replaced as this is where the cross contamination occurs. At least this is the big issue with the T6 transmission.

One option, which is much debated, and I am thinking of performing, is bypassing the transmission radiator cooler portion and go with a third party transmission cooler.

Note: Toyota, Nissan, and others have the same issue. Much negative talk on the GM/Volvo transmission - but many other auto makers have the same problem.

Do a little research on the issue so you know the pros and cons.

I would like to know if the new radiators have been redesigned - on the Nissans with similar issues apparently they have been. Maybe someone in the know can chime in.

[scot850]

Thanks for the input. The information is encouraging to know there are some good ones out there still, but equally concerning that the transmissions are poor if they can't make 100k miles. One of the issues is how they are 'flushed' causing issues releasing old varnish type debris into the oil and then going directly into the valve bodies. You also make a good point on changing out the other components due to potential contaminants in the oil coolers etc,.

It is I guess one of the things where it depends on what fails determines what needs to be replaced to be safe. Can't believe a dealer doesn't swap out several unnecessary expensive parts just to add to the profit line.

We have a load of T6's for sale around here just now, followed by 3.2 i6's and then V8's. All have there issues, but my ideal vehicle would be a 2.5T AWD with one owner and dealer history. Just missed out on one on the weekend, but then I have 2 dogs and it had the cream/light beige interior. Hm.....!

Well good to know what options are out there. Any other views on the T6 version?

Thanks,

Neil.

[SuperHerman]

Neil: A couple of follow up points. When Volvo does the repair on the transmission, from what I understand they replace everything. Second the T6 transmission usually fails because a seal failure in the radiator - so the radiator needs to be replaced as well as the transmission. The related hoses and fluid exposed parts are replaced by Volvo or they can be cleaned (third party shop or individual). Newer Volvo repaired vehicles, meaning after they finally figured out the nature of the problem, are your best bets. The original repairs were just like for like part swap repairs and the underlying problem was yet to be addressed. This is typical of every vehicle maker - until they figure out the issue - find the cause of the problem - and design the updated parts - like for like repairs are performed and generally require an additional repair. From Audi, Subaru, Range Rover and Volvo which I have owned I have seen the same pattern.

On the T6, from what I read the problem starts in the torque converter - it begins to fail and sends debris which harms the seals. I don't know if this is a fact. I do know that the Toyota and Nissan forums are loaded with owners that have the same type of issue with cross contamination caused by a similar radiator seal breach. Updated parts have solved the issue on later models.

A proper repair will have the transmission rebuilt, torque converter replaced as well as the radiator. All of these have updated parts/designs which should not fail. The T6 transmission is found in hundreds of thousands of GM cars. It is not a bad unit.

To avoid the potential problem after a repair one could just bypass the radiator portion and go direct to a third party cooler. Look at http://www.tripleedgeperformance.com/ for added information.

With that said - if you look at a T6 look at the paperwork. If the subject vehicle has been repaired correctly it is a smart buy - the bad reputation of the T6 definitely impacts the sale price. I see them for sale with over 160k on a regular basis - The highest I have seen is 220k (miles). Check to see what was replaced and what type of parts were used - the newest updated parts or the same dated parts. Call the repair shop and ask. Generally all rebuild kits use the latest parts with upgrades so if they used new service kits you should be safe.

If you really want to do it right - buy one with a bad transmission and see that all the repairs are done correctly. Not sure if you are that crazy. Triple Edge sells the transmission with all updates for about $2k including torque converter. Locally you should be able to find the same thing.

[scot850]

Definitely not that crazy. I don't know much about auto trans workings. Did look to see if there is somewhere local I could learn about how they work and how to fix. However, as yet there is nowhere offering this training. I like to learn about stuff I don't know about on Volvos/cars in general.

Volvo mostly use Aisin-Warner boxes as do many other manufacturers. All seem to have similar problems like you say.

I'm in no rush to buy, so will keep my eyes open for a (hopefully) good example that has been well loved, whatever the engine is fitted at a reasonable price (unlike dealer). I will take it to the dealer for a full inspection even if I find what I think is a good one. Worth spending the money to give a little comfort value!

Thanks again,

Neil.

[FLXC90]

Neil,
sorry I didn't see this sooner, haven't spent much time in the XC90 forum of late (Mine is parked awaiting a Water pump/TB set change due to inferior replacement pump 60k miles ago). My trans died at 120ish thousand miles, NOT glycol related at all. The common failing of the 4T65E/GT is that the T-6 is right at the rated torque limit of said trans, and the XC90 weighs a little more than the minivans it was designed for. Add AWD loads and they burn up. The friction materials and drums have a wide tolerance This results in excessive wear in the 3rd gear department, burning fluid and slipping parts effectively rendering the trans semi-operable. There is a thread by an S80 T-6 AWD guy who did a limited in-car rebuild on his. I kept my original trans to perform this on, or maybe I'll just do a full rebuild on it. I sourced a Volvo Line replacement unit from southern VoVo, and it has done well for 50thousand miles, including a LOT of towing other cars.

Triple edge performance does a lot of business with these transaxles for the performance Pontiac crowd, and it bleeds over to the Volvo market as well. One of their upgrades reduces the gap in the 3rd gear stuff to delay failure.

So, If I were looking, and there was a well-maintained (at least acceptably, since you go through everything anyway!) with a documented replacement, I would not shy away, but I also would not expect P80 simplicity or life expectancy out of it.

Oh yeah, I did have to replace my radiator at around 150, but it was due to tank/core crimp failure, nothing internal.

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