2004 S60R AWD Problem

mkiehna · Post by **mkiehna** » 05 Sep 2015, 15:30

Need any advice in diagnosing issues with my wife's 2004 S60R. I noticed the AWD was not functioning correctly this past winter. Only the front wheels were getting power. Anyway, I took the car to the dealer for a diagnosis. They stated that a new angle gear was needed at $2500. Due to my mistrust of dealers, I went ahead and purchased the collar sleeve kit and have started tearing down for angle gear removal. However, as I am trying to remove the torx bolts on the drive shaft, I noticed it is spinning freely making removal almost impossible. Now I am seconding guessing the dealer diagnosis since the the drive shaft is not in a bind and spinning freely. Could it be the AOC Haldex Pump? Any help is greatly appreciated. Alos, no major noises when the AWD stopped functioning.

rudsaki · Post by **rudsaki** » 05 Sep 2015, 17:58

I'm dealing with the same thing and have mine all apart waiting on the right sleeve kit.(they shipped the manual transmission one). My understanding is that spinning freely shows the problem. The drive shaft should always be locked into the transmission via the angle gear and sleeve/collar. It is up to the Haldex to the lock the rear differential when needed.
Due to my stupidity of eating a suction hose in my angle gear, I had to split it apart. All the gears and bearings inside were like brand new! Even though it has 150k on it, my theory is that the sleeve got stripped very early in the car's life and it has been FWD ever since.
If the yoke of your angle gear does not have any up and down play in it and turns smoothly, it is probably ok.

Post by **JRL** » 06 Sep 2015, 08:40

You ALWAYS should pull the codes first.
If there are no codes than it's almost always the angle gear/collar sleeve.
Bear in mind that over 75% of the time, the splines on the angle gear are also stripped enough that replacement of both is necessary.