Prop shaft and Haldex service '07 XC70

[erikv11]

I decided to run a separate thread on the front half of the AWD in hopes of faster, specific responses to those questions, please see viewtopic.php?f=9&t=96149

[erikv11]

OK the Haldex is back together with new pump, coupling dampener is back on. I'll fill the pump fluid once I get the angle gear and prop shaft back on.

For releasing the prop shaft and removing the rusty AOC coupling the key tools were
(1) Blacklab's thread including great posts from Pete viewtopic.php?f=9&t=94282
(2) impact wrench
(3) impact hammer with long (about 12 inches), pointy bit
(4) spare M8 socket head cap screws, one short one (maybe 10 mm) and one long one (maybe 25 mm)

For removing the prop shaft CVs from the couplings, for both ends of the prop shaft I used the non-threaded holes in the dampers, and put in the short socket head cap screw. The pointy bit on the air hammer goes into the hex recess in the screw head and then the prop shaft pops free pretty quickly. Move to the longer screw if needed. I've done two prop shafts this way now, so it is 4/4 on releasing those rusted CV ends.

For removing big rusty coupling from the AOC box I first removed the shallow 24mm nut with an impact gun, then put the socket head screw in one of the same non-threaded holes in the coupling and popped it right off with the air hammer. You can alternate sides if the coupling is stuck on the shaft, as there are non threaded holes 180 degrees apart. Just remove screw, rotate coupling, insert and hammer it.

[Jonkalb6109]

my 2006 xc90 Haldex has a hex head drain plug, at least it appears to be a drain plug but i can not break it loose. I have tried soaking it with pb blaster and Im afraid its going to strip. Is this the fill port ? i dont see another spot to fill with fresh fluid.

[Blacklab467]

The fill plug will be on the left hand side of the Haldex unit, mines a 2003 and it was a large hex head I would guess 6 or 8. It will be forward of the Differential drain plug which I believe is a 10 or 12 mm bolt. There is no drain plug, You have to suck the fluid out or remove the Haldex pump to drain it fully. You can break it loose, just man up and put some muscle into it, maybe use a 1/2 inch drive.

[Blacklab467]

Or a 13mm

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[erikv11]

On my 07 XC70 the Haldex fill plug faces the driver's side of the Haldex, 13 mm.

On my 07 XC70 the rear diff fill plug is around the back side of the diff facing the rear of the car, 13 mm. Design change compared to the 03.

[erikv11]

Test driven only 15 miles but all seems working, no codes etc., seems this one is done.

TLDR recap: Had no AWD and DEM007 code. Tested pump on car with by giving it 12V, pump was dead. Replaced pump, filter and Haldex fluid. Used Volvo brand on all three. On the prop shaft I popped the tin caps off the CV joints, the grease looked fine but scraped out what I could (no solvent used) and packed with fresh CV joint grease. Nothing else replaced.

For the Haldex fluid, after replacing the pump I first filled the Haldex case until fluid spilled out the fill hole. Then replaced the fill plug. After completely putting the car back together but with the car still on four jackstands I started it up and move through the gears, assuming this would fully send fluid to the pump and filter housing. Nice to see the rear wheels moving! Anyway then I pulled the fill plug and added more fluid - the case accepted another 80 mL fluid before it started dribbling out again. Replaced fill plug and I'll check it again in a week or so but I'm thinking it may be topped off now.

[Blacklab467]

Check the manual, I think you need to remove 50 or 100 millilitres after it’s full unless they changed that on the ‘07.

[Blacklab467]

Nicely done BTW! And just in time for winter.

[erikv11]

Check the manual, I think you need to remove 50 or 100 millilitres after it’s full unless they changed that on the ‘07.

Oops ok I will, thanks.

Nicely done BTW! And just in time for winter.

Thanks for the help!

We got 7" of snow today ...