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2005 XC70 - Convert to FWD Topic is solved

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renns
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Volvo Repair Database 2005 XC70 - Convert to FWD

Post by renns » Sun Mar 20, 2016 8:49 pm

I have been driving my 1998 V70 AWD as a FWD for more than 150k kms by removing bevel gearbox and driveshaft. I did have to bond the drive sleeve into the transmission to seal it up, but other than that, it was a straight-forward removal, and I've had no issues since. I'm now looking at getting a newer Volvo to replace this old girl as I'm up to around 360,000 kms now. What I'm wondering is if newer AWD Volvos can be converted to FWD as easily as my old '98? There is a low mileage 2005 model for sale locally with bad bevel gearbox that might make a good addition to the fleet if it can be converted to FWD easily. If replacement of the gearbox is the only option, the car is much less appealing due to replacement costs.


1994 850 5-speed wagon, retired at 400,000 km
1998 V70 AWD 5-speed, retired at 358,000 km.
2005 XC70 275,000 km - daily driver

renns
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Re: 2005 XC70 - Convert to FWD

Post by renns » Tue Mar 29, 2016 8:38 pm

OK, I picked up the XC70, 90,000 miles, in very nice shape overall. I had it towed home yesterday, put it up on stands tonight, and pulled the driveshaft and bevel gearbox. The rear driveshaft seems to be in useable condition, although the CV's in each end seem stiff and likely need re-packing. The problem, however is the bevel gearbox as reported by the previous owner. The output to the rear driveshaft was very loose, and oozing gear oil.

I've attached a few pictures. It looks like there really are no user-serviceable parts inside. The gears have tooth damage, and the bottom of the housing was full of roller bearing pieces. At the split line on the housing there was some grey assembly paste that didn't seem to be 'factory' installed. Looking at the cover casting, it appears this box has been apart to modified and re-sealed per Volvo's TNN 'Angle Gear Fluid Leakage'. It's not a good sign that the box has failed now, with so few total miles on the car.

In any case, the question now is what to do... I am on the search for a replacement box locally, but am wondering about driving this car in the meantime. The drive collar stayed in the transmission, and I can make up a keeper to retain it like I did a few years back on my old V70, so that's not a concern. My only reservation is with regards to setting codes/warning lights. Will pulling the AWD fuse prevent that? I'm hoping to lure a reply to two with the pics below!
WP_20160329_21_45_17_Pro (Medium).jpg
WP_20160329_21_46_19_Pro (Medium).jpg
WP_20160329_21_45_25_Pro (Medium).jpg
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1994 850 5-speed wagon, retired at 400,000 km
1998 V70 AWD 5-speed, retired at 358,000 km.
2005 XC70 275,000 km - daily driver

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Re: 2005 XC70 - Convert to FWD

Post by abscate » Wed Mar 30, 2016 3:49 am

I haven't seen a lot of P2 fwd conversions but let's give the forum a week to see what it dredges up....


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Re: 2005 XC70 - Convert to FWD

Post by renns » Wed Mar 30, 2016 5:52 am

I'm surprised to not find information about the fwd conversion, as they are so common with the earlier cars. I have read numerous reports of awd failures where the splined coupling strips, effectively disengaging the drive to the rear. These owners report no dash lights, and no indication of the failure until they spin the front tires. Assuming that's the case, just pulling driveshaft, or in my case driveshaft and bevel gearbox, should do the trick.


1994 850 5-speed wagon, retired at 400,000 km
1998 V70 AWD 5-speed, retired at 358,000 km.
2005 XC70 275,000 km - daily driver

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Re: 2005 XC70 - Convert to FWD

Post by precopster » Wed Mar 30, 2016 2:42 pm

The FWD transmissions can be turned into AWD by using an AWD (not XC) passenger side shaft and adding the sleeve and angle gear. It's documented here on MVS.

The problem with the reverse of that is you need a longer passenger side shaft after the output sleeve is removed to accomodate the wider track due to the different (XC) control arms. Longer passenger side shafts for XCs are not produced.

You could have one made up and expertly balanced and the increase in length would be equal to a FWD to XC shaft difference however it would need to be well done.

The flip side of this is you could remove the sleeve and place FWD or AWD (not XC) control arms and shocks on the car and use a standard FWD driveshaft.

Or just simply buy a good used angle gear...........


Current cars:2002 XC70, 2006 Ssangyong Rodius (Stavic), 2006 XC90 2.5T, VW Transporter 2.5TDI

www.precisioncarmodules.com.

renns
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Re: 2005 XC70 - Convert to FWD

Post by renns » Wed Mar 30, 2016 3:13 pm

Sorry Mike, but I don't understand what you're saying in that post. Are you sure you don't have that reversed??? Mechanically converting from AWD to FWD is near-trivial - just remove the offending parts (propshaft and bevel gearbox), figure out a way to keep the drive sleeve in place to close up the transmission, and stick the original passenger side shaft back in place. There are no geometry changes for the shaft. It passes directly through the inside of the bevel gearbox, so it matters not if the bevel gearbox is actually present. I did this mod on my '98 and it's served me well for many years.

I would like to see how someone converts a FWD transmission to AWD. To my understanding there is no provision for output sleeve??

I'm confident in the mechanical aspects of the conversion - it's the computer/codes issues I'm concerned about, as the newer cars have a much 'smarter' AWD system than my old '98.


1994 850 5-speed wagon, retired at 400,000 km
1998 V70 AWD 5-speed, retired at 358,000 km.
2005 XC70 275,000 km - daily driver

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Re: 2005 XC70 - Convert to FWD

Post by precopster » Thu Mar 31, 2016 6:01 am

There's a post on converting a P2 XC trans to a FWD here on MVS (quite recently) The casing had to be split to remove the sleeve.

To my understanding the splined output for the passenger side shaft or RHS is provided by the bevel gear.

I have been trying to get my head around how to convert my XC to FWD because FWD boxes are easier to find and cause less issues however the answer I gave you is what I received from asking what you asked on here and Swedespeed.

Taking a look at my 2001 T5s RHS driveshaft and comparing it to my 2001 XCs driveshaft shows a vastly different length and the control arms on a P2 XC are much longer to accomodate the wider guard flares and increased track.

Look up the part numbers for P2 series XCs and then a P2 series FWD control arms. Different shape and different part numbers.


Current cars:2002 XC70, 2006 Ssangyong Rodius (Stavic), 2006 XC90 2.5T, VW Transporter 2.5TDI

www.precisioncarmodules.com.

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Re: 2005 XC70 - Convert to FWD

Post by renns » Thu Mar 31, 2016 9:36 am

Hi Mike,

OK, I see you are talking about swapping to FWD transmission as well. I am leaving the AWD transmission in place, and just removing the bevel gearbox and propshaft. The drive sleeve that couples the bevel gearbox to transmission must remain in the transmission to seal the annular opening that would otherwise open the transmission to the elements. As the drive sleeve on my car is tightly locked into the trasmission now, I plan to leave it in place, and use some external retainer as insurance to keep it in place. On my old V70 I did this with a metal retaining bracket. On this car, I think I'll just use the double hose-clamp idea posted by another forum uesr, I think 8pack?


1994 850 5-speed wagon, retired at 400,000 km
1998 V70 AWD 5-speed, retired at 358,000 km.
2005 XC70 275,000 km - daily driver

precopster
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Re: 2005 XC70 - Convert to FWD

Post by precopster » Thu Mar 31, 2016 10:42 am

You still haven't mentioned how you will fimd a shaft long enough for the increased track on a P2 XC.

The RHS driveshaft on an XC P2 picks up drive from the angle gear, not the transmission.

So if you put a P2 FWD shaft in place it will be too short because of the extra track on P2 XCs.


Current cars:2002 XC70, 2006 Ssangyong Rodius (Stavic), 2006 XC90 2.5T, VW Transporter 2.5TDI

www.precisioncarmodules.com.

renns
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Re: 2005 XC70 - Convert to FWD

Post by renns » Thu Mar 31, 2016 11:09 am

precopster wrote: The RHS driveshaft on an XC P2 picks up drive from the angle gear, not the transmission.
I don't think this is true. The RHS driveshaft I removed from my '05 XC passes right through the bevel gearbox, engaging in the transmission in the same fashion as my old '98 V70 AWD. I'm going to stick that driveshaft back into place tonight when I get a chance to reassemble the car. I'll add some pics later to further document this process.


1994 850 5-speed wagon, retired at 400,000 km
1998 V70 AWD 5-speed, retired at 358,000 km.
2005 XC70 275,000 km - daily driver

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