The dreaded Angle Gear- some advise please!

[volvooh]

After dealing with an Anti-Skid issue for the better part of 2 months and no AWD, I thought that when I solved the Anti-Skid issue my lack of AWD problems were solved. I still have no AWD. I am not getting any codes from the DEM and when I look at the live data feed it looks happy and ready for action. I can very easily turn the rear drive shaft by hand which makes me think I've got a sleeve/ bevel gear issue.

So here's the rub: The PO stated he replaced the bevel gear (he used a pull off) and welded the sleeve to the gear. How is this going to complicate the repair? I am I going to need a new bevel gear and prop shaft/sleeve? I was kind of hoping to farm this job out to my local indie as I have too many other projects that need done in the near term. How many shop hours should I expect to get this job done?

[ggleavitt]

If you can turn the driveline by hand with all four wheels on the ground, you have a stripped angle gear input shaft or a stripped sleeve or both.

If the sleeve was welded to the input shaft and is still whole, then transmission output splines "could" be stripped (might not be, this is an AW5 transmission so softer sleeve). I had to go back into some of your earlier posts to see that this is a 2005 2.5T which means that you may be able to get the angle gear off with the sub-frame left in place (someone please correct if this is wrong).

I replaced the angle gear on my '08 Sport (stripped out in 2015 after 6 months of ownership) and have an OE "exchange" angle gear sitting on a shelf for what I assume to be an eventual replacement in the '06 Ocean Race.

Only way to really find out is to pull the angle gear and see the mechanical connection path, then you can decide on the approach. Volvo exchange angle gears run around $1500 plus $100 core, you could try and find a used gear from another '05 (there are a few PNs for this item) but it needs to have really good input splines of you'll be back where you started sooner than later.

Couple photos, this is what a stripped angle gear looks like (TF-80SC transmission with hardened sleeve):

Gear (splines are stripped out, upper part where you see the untouched spline is the space at the very back end of the sleeve):

IMG_2079.JPG (166.02 KiB) Viewed 8119 times

Sleeve (see open space at back where gear input splines do not contact as noted in the first photo)

IMG_2075.JPG (241.77 KiB) Viewed 8119 times

[Masscomguru]

If the PO welded the sleeve to the gear, that would be a permanent fix.. Either the welds failed, or something broke deeper. I would just plan on a new angle gear

Gah! G beat me.

[volvooh]

Thank you. My indie is quoting me about $350 in labor out the door, which I think I'd be inclined to go with. Assuming I can find a pull off angle gear in good condition, what are the other required parts? I assume the exhaust gets dropped, so will I require any exhaust gaskets? I assume if I call a volvo dealer I can get the part# required for my vehicle? On ebay it looks compatible with other Volvo AWD models- S60, V70, S80.

[ggleavitt]

PN 36000340 for the Volvo exchange angle gear, compatible with a number of other 5 cylinder P2s of the same general MY range:

Volvo S60 2003, 2004, 2005, 2006, 2007, 2008, 2009
Volvo S60 2.5l 5 cylinder Turbo 2006, 2007
Volvo S80 2003, 2004, 2005, 2006
Volvo V70 2003, 2004, 2005, 2006, 2007
Volvo V70 2.5l 5 cylinder Turbo 2006, 2007
Volvo V70 XC 2.5l 5 cylinder Turbo 2003, 2004, 2005, 2006, 2007
Volvo XC90 2.5l 5 cylinder Turbo 2003, 2004, 2005, 2006, 2007

Assuming an angle gear replacement is in your future, it's really important that you get a unit with good input splines, bears repeating. You need to be really picky about this if you want the repair to last.

Job is pretty straight forward, you'll want to review VIDA if you can to see the method they suggest for the R&R but it can be done without dropping the sub-frame.

Assuming the transmission side is whole and all that you’re replacing is the angle gear, you'll want service kit PN 31437982 which contains a new sleeve and seals.

Last but not least, LOTS of grease in the space between sleeve and spline. Kit should come with grease PN 1161748, instruction in VIDA is to use the entire tube.

Good luck with your repair.

[cn90]

The Volvo P2 AWD system was an engineer after-thought.
It was poorly designed.
Why fix something, spending a lot of time, only to find out it will fail again?

For my 2005 XC90 AWD 2.5T, the angle gear is stripped.
I simply ignore it, install winter tires and done with.
So yes, my XC90 is now a FWD vehicle.

[volvooh]

cn90- That is definitely a consideration. I am also concerned that I spend the $$ only in a year or 2 to be back in this same position. If I am to believe the PO, the Angle Gear and sleeve were replaced 2.5 years ago. I'd estimate less than 40k mi on that repair. I am a huge volvo guy, and I bought this because I require a vehicle with 4WD that works. The fact that right now it doesn't may lead me to move on to something that has full time 4WD and not a slip differential.

But I really do like this vehicle, so if I move forward with this repair, I assume to exhaust needs to be dropped/ removed. Are there any gaskets or supplies required to reinstall the exhaust?

[ggleavitt]

Don’t see in VIDA that the exhaust needs to come off and I no longer have my ’05 to go out and do a visual validation. Oil cooler comes off to make room for the R&R, you’ll want qty. 2 of PN 30637339 sealing ring on the replacement.

[blanketbum]

Thank you. My indie is quoting me about $350 in labor out the door, which I think I'd be inclined to go with. Assuming I can find a pull off angle gear in good condition, what are the other required parts? I assume the exhaust gets dropped, so will I require any exhaust gaskets? I assume if I call a volvo dealer I can get the part# required for my vehicle? On ebay it looks compatible with other Volvo AWD models- S60, V70, S80.

You should definitely buy the exhaust flange gasket and it's not necessary to remove the downpipe but if he decided to you'll need a turbo to downpipe gasket (P#: 8642449).

[ggleavitt]

Gasket for cat to exhaust is PN 8672278.