Angle gear and collar opinions sought '07 XC70

[erikv11]

OK so while servicing the Haldex (viewtopic.php?f=9&t=96141) I was thankfully goaded into pulling the angle gear to check and possibly service that if needed while the prop shaft is out. I'm making a separate thread here on the angle gear to seek opinions on the condition of the splines on the angle gear and collar.

Here's my impressions, seeking feedback:

(1) Angle gear shaft the splines looks good, have just a bit of wear, so change the fluid and feel good putting it back in. Agree or disagree?

(2) Collar the splines are about half worn, safe bet is to replace it but still a lot of life left if you don't change it. Agree or disagree? What would you do?

(3) Side note - the collar is stuck, any favorite methods to get it out of the trans case? On my S60 R with the auto box the collar just slipped right out no issue at all, so I was surprised to find this one stuck on the XC70. I'm a little concerned that the passenger axle shaft was dusty with rust not wet with trans fluid, might this suggest the collar is rusted on to the trans output shaft?

Pics, angle gear shaft:

Angle gear 1

Angle gear 2

Pics, collar:

collar 1

collar 2

collar 3

[oragex]

There's a few interesting videos on youtube about removing the sleeve

[Blacklab467]

That Bevel Gear actually shows no signs of wear, the collar sleeve obviously has a little bit starting. Usually the BG will have a shark tooth on the end of the splines where the collar doesn't make contact but yours are nice and flat so that's good. I would change the oil and throw it back together.
If you were insistent on removing the Collar sleeve such that you could reuse it you would need to use the volvo puller. I don't think there's any merit in removing it right now if you're going to run it for a couple more years, the seal doesn't appear to be leaking.
The collar likely isn't rusted to the trans output, its just a really tight (maybe interference) fit. That rusty goo on the inside of the collar and BG is pretty normal.
Sorry for goading you into taking it apart but at least now you know, I'd say it's in great shape and good for a few more years! It's a Christmas miracle!

[erikv11]

To be clear - thanks for the goading! At 170k it needed to be looked at.

It’s this dry rust on the half shaft that puzzles me. Expected it to be wet with trans fluid.

[Blacklab467]

I would be more concerned if it was wet with trans fluid, the splined end goes into a dry female spline in the bottom of the trans, as does the drivers side. That being said, I've not seen one with that much rust but I wouldn't worry about it. The seal on the inside of the collar sleeve appears to do little more than preventing water ingress laterally along the axle shaft as far as I can tell.
If you really want to get the collar sleeve off your could put a couple shallow grooves in it and tap it off, as shown in the picture and still use the collar sleeve after, you won't damage any sealing surface. There really isn't any reason to though if you're going to use it going forward, there's nothing to see and no guarantee that it will come off easily.
All that being said, I've not seen a used BG with splines that good and I've been scouring the boneyard for months!

Sleeve.jpg (25.98 KiB) Viewed 247 times

[erikv11]

... the splined end goes into a dry female spline in the bottom of the trans, as does the drivers side. ...

Aha, that's different from the TF-80SC trans on our S60 R. There the passenger side female spline is bathed in transmission fluid. The collar seals are both important to keep the trans fluid from leaking. Have never seen the driver's side.

So with this trans, when I re-pack the angle-gear-to-collar junction with grease is it so important to keep the axle end dry and free of grease? With the TF-80SC you do that to keep the grease from contaminating the trans fluid.

[Blacklab467]

Yeah its totally different, I would rather have the 6 speed though, it's rated for about twice the torque as the Aw55-50!

[erikv11]

Angle gear went back in after some bench press tetris, car is back together and running with no problems.