Angle gear problems

[XC90driverlady]

I've got a 2010 Volvo XC90, it's a V6 and AWD. A little background info on my dilemma: I was sitting at a red light, on a slight incline, I accelerated to make a right turn and I heard a loud bang (my dad said it sounded like a shock bottoming out) and the car jerked a bit. On the drive home, every time I let up on the gas, the car made a rythmic thumping noise.

I took it in to the dealership and they said I needed a new angle gear. I have a comprehensive after market warranty, but the warranty company wouldn't let Volvo use a new part. They wanted to send a used part for Volvo to put in. The dealership balked and charged me a 10% parts markup, the warranty company was a nightmare, and I was stuck between a rock and a hard place bc it was an expensive repair. Anyway, the dealership installed the used part, I got my car back and here is where my current dilemma stands:

When I accelerate and then take my foot off the gas, the car makes this really low rumble, almost like I've shifted into a lower gear. It maintains this low sound until I step on the accelerator again. AND, sometimes, when I make right hand turns I will hear the same loud noise that I heard when the angle gear first broke. The sound comes from the back of the car and it sounds like something bottoming out. I want to take the car back to the dealership before the after market warranty is up, but it's sort of far away and quite a hassle with my kids and husband's work schedule. Any idea what's going on or what I should tell the dealership? I feel like bc the problem doesn't happen every time I turn right, they won't hear it and I'll have made a pointless trip. Also, not sure if this makes a difference, but when the dealership gave me back my car, they didn't align it. My steering wheel is tilted sideways when my car is pointed straight ahead. My husband noticed when he drove the car a few days after I brought it back from the dealership. Any advice welcome!

[ggleavitt]

Take it back, with the list of specific complaints (the steering wheel skew is just plain ignorance, should have been alignment once the subframe was removed, and the wheel position is easy to check before and after). Car tracking left or right? That might suggest an alignment was NOT done after the subframe was replaced.

I would tell them to give you a loaner sufficient for your needs and to call you when everything is fully and completely fixed.

Not cool that you have to go through this on your own, let them fix what they have yet to truly fix. Worse if this is a Volvo dealer, they should be replacing with an OE "exchange" part which, more often than not, is a rebuilt unit to new spec. I have one of these in my '08, looked perfect when it went in, new input shaft splines and all.

But take it back regardless, it's a paid repair to your car one way or another and needs to work properly.

On another note, can see link http://forums.swedespeed.com/showthread ... gle-Gear-) for a few photos of what it looks like when they fail, at least for spline/sleeve stripping.