DIY: 2005 Volvo XC90 2.5T: ATF, Angle Gear, AOC/RDiff Fluid

[nascenta]

Thank you for doing this. It is still being referenced!

[Sssz]

Is the location of the fluid changes for the 2005 XC90 the same as 2010XC 90?

[Nicodemus0]

Thanks again to the OP for posting all the detail on this. Bought my '06 XC90 2.5T a year ago, now at 107k, and just finishing getting everything up-to-date based on everyone's guidance here. This week had the three differential fluids and AOC filter changed by my local Volvo independent shop, all with OEM fluids/parts purchased online. In the event it helps others, here are the most up-to-date Volvo part numbers and my costs for everything (YMMV), as many have changed since the original post:

Angle Gear Fluid (#31367237): $26.07/L
AOC/Haldex Fluid (#31367941): $18.98/L
AOC Filter (#30787687): $22.45
Rear Differential Fluid (#31367238): $17.73/L

For what it's worth, labor charge was $80.

[MadeInJapan]

Thanks for the write up... I have a AWD '07 S40 manual transmission.
This stuff seems the same with my car and the info here helps a ton.
To the last poster: Nicodemus0 I noticed you have an Angle Gear Fluid listed.
I did not have that in my basket at FCP so I added it. The Volvo regular manual transmission fluid (#31280771)- 2 liters worth was in there instead. Can this not be used for the angle gear too, or is the one you listed recommended (#31367237) which FCP lists now as part #31259380? I'm a bit confused as to where the angle gear is- is it up front and is still separate from the transmission that is accessed near the front left axle shaft spindle? Remember that I'm talking about a manual transmission and you might be talking about an automatic. Thanks for any help on this!!

[Turbo_Boss]

So just curious

Is there is a Aftermarket Oil I can use on the AOC System instead of the Volvo one PN 31325136, Volvo sells this for $18/L.

THX

Isaac

[camshaft190]

Long time lurker, first time poster here...

Thanks for this writeup, great pics and detail!

One remaining question I have is the fill amounts for each item, Angle Gear, AOC and rear differential. In the event someone has a weep/leak they will not want to replace exactly what was removed. I have read other notes on this and it appears that you should be filling to the hole then remove a certain value, for example .1l ( 100ml).

One post mentioned that 160ml should be removed from angle gear, then 100ml each for AOC and rear diff.

Does anyone know the precise amounts that should be withdrawn once the level is even with the fill hole? I am a bit lost on what subscription I would need to VIDA to get this info (the only info I need at the moment). Any insight would be appreciated. I am not sure if there are different specs for each year but I am looking for the fill values (not capacity) on a 2006 XC90 2.5t awd.

I apologize if I missed it somewhere but I cannot find these values for the life of me.

Thanks in advance

[marmotteNZ]

+1 for camshaft quesiton above!

[AMITOFO]

Hi cn90

Thank you so much for this great post!!

I've recently bought a 2004 XC90 T6 AWD @79K miles - and suspect PO did the same - didn't service these or changed fluids. Which might explain why the AT failed in 2016 and the PO had to spend a fortune to rebuild the AT!

I'm now contemplating on the jobs you've posted above!

Hope you don't mind me asking a few silly questions (I'm almost a complete newbie):

1) Am I right to understand from the diagram above - that the AT and Front Diff share the same fluids (ATF) - which is why you didn't specifically document changing Front Diff fluid? If so, I won't bother with Front Diff fluid - as the AT was rebuilt only a couple of years ago and the fluid colour is very clean.

2) After you drained the AT, did you change the green clips on both upper and lower lines (I'd assume so - but since you didn't explicitly mention changing upper line's clip - thought I'd ask to clarify).

3) After you changed the AOC filter - did you encounter any error codes? Can't remember where but I recall reading on other forums folks who serviced AWD filter (I'd assume AWD filter is the same as AOC filter??) had funny codes that were tricky to erase... I do have a VIDA but just want to find out if this is a possibility.

4) Last, how far is the Rear Diff / AOC fluid bolts from the AOC filter? I've managed to find the AOC filter by chance - but not the drain bolts (admittedly I didn't look hard enough for them)

Thank you so much in advance!
Namo Amituofo

[AMITOFO]

Long time lurker, first time poster here...

Thanks for this writeup, great pics and detail!

One remaining question I have is the fill amounts for each item, Angle Gear, AOC and rear differential. In the event someone has a weep/leak they will not want to replace exactly what was removed. I have read other notes on this and it appears that you should be filling to the hole then remove a certain value, for example .1l ( 100ml).

One post mentioned that 160ml should be removed from angle gear, then 100ml each for AOC and rear diff.

Does anyone know the precise amounts that should be withdrawn once the level is even with the fill hole? I am a bit lost on what subscription I would need to VIDA to get this info (the only info I need at the moment). Any insight would be appreciated. I am not sure if there are different specs for each year but I am looking for the fill values (not capacity) on a 2006 XC90 2.5t awd.

I apologize if I missed it somewhere but I cannot find these values for the life of me.

Thanks in advance

Hi, not pretending to know better than you - as I've yet to do these jobs myself for the 1st time - but if you search on Youtube for a video called 'servicing haldex AWD on a volvo' by a guy called 'volvosweden' - he went through the processing of driving the car for a while and removed some fluid - after filling to the brim of the fill hole.

Cheers
Namo Amituofo

[SethP]

Worth noting that I have done the angle gear and rear differential on my 2013 XC90 3.2 AWD.

The angle gear on this model looks quite a bit different than the one shown in the pic, but it's actually even easier to get to. Just a vanilla simple 3/8 ratchet with the correct socket will remove the plug.