Overfilled angle gear causing leak?

[darrylrobert]

since fitting my replacement used angle gear ive been monitoring a leak from the large o ring. I purchased a new o ring and today set about replacing it, first big mistake i made was doing the job in reverse order 1)remove driveshaft 2)check fluid level and yes a fair amount of fluid poured out...would this excess fluid cause it to leak?..car front up in air not back.

Anyway since i had already taken half the car apart i went ahead and replaced the o ring, i was stressing out about it because i knew i would struggle counting the turns and yes i did, the saving factor is i took photos before so had something to compare to. It turns out that with each revolution the nut moves inward a noticeable amount so one rev under or over would be obvious. Actually you can replace the o ring without fully removing the nut, it was almost doing this but wanted to properly clean the groove the o ring sits in (OCD)

picture: so a full revolution you will see close to 2mm difference in its position, i counted 9 full revolutions plus about 15degrees, thats what confused me.

angle gear nut

angle gear nut.jpg (114 KiB) Viewed 220 times

[ignatz]

My 2001 V70t5 stick shift car developed a slight oil leak after I filled up the oil level to the filler plug. Too much oil, not the specified amount. That car got totaled, and after that I got a 2006 S60 2.5T awd, I had the fluid changed in the front and rear differential units. The car needed something else soon after that service work at the same shop, and they said my rear differential was leaking. I argued with them about fluid levels and they said that they always fill them up to the top. I took the car home, parked it on a portion of my steep driveway and opened the plug to release some fluid. After that, no more oil leak.
When I do transmission drain and fills on my cars, I pour the old ATF into a graduated 3500 ml beaker (big), get a calculator out and figure how much oil to put back in. That's usually 3.3 to 3.4 quarts per drain and fill.
So, I would be one to believe overfilling would cause a leak.

[SuperHerman]

If I recall there are several discussions on proper fill procedure. I believe the final consensus was to fill to the top and then remove 100ml.

Too much fluid could cause a leak as the pressure will be higher (but my recollection is there is a vent on the unit - it has been a long while since I have done one). Read up and come to your own conclusion on proper fill level - if you decide it is full to fill hole minus 100ml it is easy to get to that point. Then see what happens.

As to the tension set on that large nut - if you marked the correct spot then per your photos the alignment ear looks good and the gap tab ears to ring looks about the same. I usually put a scribe mark via scratch, paint or sharpy for reference and measure the protrusion or recess. Counting turns is tough because it is so hard to tell when it actually engages/disengages the first turn

[Skymongrel]

I had a leaky angle gear too earlier this year. Mine was a 2006 XC70 with 165k. Leak was small but persistent and turned out to be the o-ring behind that toothy adjuster nut. I bought the removal tool for piece of mind, but this did allow me to torque it to spec. I too ended up with more turns than what I had originally. Here is link to my posts regarding this; https://www.matthewsvolvosite.com/forum ... =9&t=93213

Hope this helps!

[SuperHerman]

Skymongrel - what was the torque spec for the "adjuster nut". My experience tells me that if the correct ear was marked the OP has to be off at least 360 degrees if this is the issue. Assuming OP has some experience with using torque specs, the mating surfaces were clean and the "adjuster nut" threaded down smoothly an actual torque spec could supply some guidance and clues.

[Skymongrel]

My experience was that it took about 9 revolutions to remove the adjuster nut and I ended up using 9 1/2 to tighten it with new o-ring installed. Somewhere I found a torque spec that said 36 ft. lbs. was right using the removal tool. I don't have Vida or any manual that I can research but I haven't had any leaks since.

[darrylrobert]

UPDATE: its now leaking from the shaft seal, the one in the middle that sits between the angle gear shaft and castellation nut, i assume it got upset with being removed. I just rang my parts dept. and this part will cost $100aud (approx $75USD) twice the price of what you pay in the US. Anyway was replacing this seal to be expected i dont hear others mention replacing other seals or have i been unlucky?

angle gear seal

s-l500.jpg (24.03 KiB) Viewed 140 times

[darrylrobert]

I just bought the Corteco brand seal for $8usd plus $20 delivery to Australia, i believe thats the brand volvo use but without the $30 pretty blue box?