Prop shaft and Haldex service '07 XC70

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive P2 platform cars sold as model years 2001-2007 (North American market year designations).

2001 - 2007 V70
2001 - 2004 V70 XC (Cross Country)
2004 - 2007 XC70 (Cross Country)
2001 - 2009 S60
2003 - 2007 S60 R
2004 - 2007 V70 R

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erikv11
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Re: Prop shaft and Haldex service '07 XC70

Post by 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
'95 854 T5-R, Motronic 4.4, 185k
'96 855 NA, 145k
'98 S70 NA, 220k (living out west)
'98 V70, T5 tune-injectors-turbo, LPT engine, 293k
'06 S60 R, 167k
'07 XC70, 170k
'99 Camry V6 :shock: 130k
gone: '96 NA 850 210k, '98 NA V70 182k

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erikv11
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Post by 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.
'95 854 T5-R, Motronic 4.4, 185k
'96 855 NA, 145k
'98 S70 NA, 220k (living out west)
'98 V70, T5 tune-injectors-turbo, LPT engine, 293k
'06 S60 R, 167k
'07 XC70, 170k
'99 Camry V6 :shock: 130k
gone: '96 NA 850 210k, '98 NA V70 182k

Jonkalb6109
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Joined: Tue Dec 01, 2020 7:50 pm
Year and Model: 2006 xc90
Location: Virginia

Post by 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
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Year and Model: 2003 xc 70
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Post by 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.
2003 XC 70, 2007 Duramax LBZ.

Blacklab467
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Post by Blacklab467 »

Or a 13mm
Screen Shot 2020-12-28 at 8.44.05 PM.png
Screen Shot 2020-12-28 at 8.44.05 PM.png (312.18 KiB) Viewed 219 times
2003 XC 70, 2007 Duramax LBZ.

User avatar
erikv11
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Post by 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.
'95 854 T5-R, Motronic 4.4, 185k
'96 855 NA, 145k
'98 S70 NA, 220k (living out west)
'98 V70, T5 tune-injectors-turbo, LPT engine, 293k
'06 S60 R, 167k
'07 XC70, 170k
'99 Camry V6 :shock: 130k
gone: '96 NA 850 210k, '98 NA V70 182k

User avatar
erikv11
Posts: 10219
Joined: Sat Jul 25, 2009 2:03 pm
Year and Model: 850, V70, S60R, XC70
Location: Iowa
Has thanked: 138 times
Been thanked: 376 times

Post by 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.
'95 854 T5-R, Motronic 4.4, 185k
'96 855 NA, 145k
'98 S70 NA, 220k (living out west)
'98 V70, T5 tune-injectors-turbo, LPT engine, 293k
'06 S60 R, 167k
'07 XC70, 170k
'99 Camry V6 :shock: 130k
gone: '96 NA 850 210k, '98 NA V70 182k

Blacklab467
Posts: 288
Joined: Tue Aug 09, 2016 4:25 pm
Year and Model: 2003 xc 70
Location: Calgary, AB
Has thanked: 14 times
Been thanked: 25 times

Post by 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.
2003 XC 70, 2007 Duramax LBZ.

Blacklab467
Posts: 288
Joined: Tue Aug 09, 2016 4:25 pm
Year and Model: 2003 xc 70
Location: Calgary, AB
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Post by Blacklab467 »

Nicely done BTW! And just in time for winter.
2003 XC 70, 2007 Duramax LBZ.

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erikv11
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Joined: Sat Jul 25, 2009 2:03 pm
Year and Model: 850, V70, S60R, XC70
Location: Iowa
Has thanked: 138 times
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Post by erikv11 »

Blacklab467 wrote: Tue Dec 29, 2020 5:18 pm 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.
Blacklab467 wrote: Tue Dec 29, 2020 6:42 pm Nicely done BTW! And just in time for winter.
Thanks for the help!

We got 7" of snow today ...
IMG_0561.jpeg
'95 854 T5-R, Motronic 4.4, 185k
'96 855 NA, 145k
'98 S70 NA, 220k (living out west)
'98 V70, T5 tune-injectors-turbo, LPT engine, 293k
'06 S60 R, 167k
'07 XC70, 170k
'99 Camry V6 :shock: 130k
gone: '96 NA 850 210k, '98 NA V70 182k

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