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2005 xc90 t6

A mid-size luxury crossover SUV, the Volvo XC90 made its debut in 2002 at the Detroit Motor Show. Recognized for its safety, practicality, and comfort, the XC90 is a popular vehicle around the world. The XC90 proved to be very popular, and very good for Volvo's sales numbers, since its introduction in model year 2003 (North America). P2 platform.
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AndyO
Posts: 1
Joined: 1 September 2023
Year and Model: 2005 xc90 t6
Location: Southampton

2005 xc90 t6

Post by AndyO »

Hopefully someone can give me a bit of help.
Just picked up a 2006 xc90 t6, it has gearbox problems.
I had budgeted a second hand ebay gearbox into the price, but was going to do a full flush and the shift kit, in hopes of a cheap repair.

Only code was p0734 (4th gear slippage). I cleared it with a generic code scanner, theres now no dash warning lights. (Previously said “transmission service urgent). car would not move in any gear, even manually cycling through the gears with engine running (only r, n, d, 1,2,3 are selectable, wont go into 4th, even with code cleared, and as said, no warning lights).

However it seems like a complete idiot has been working on this car. The drivers side driveshaft has a bolt overtightened, that has stripped the threads. Others seem pretty close to being stripped. and theres a leak from the front of the transmission , but i cant see where its from.
Ive tightened what i can see, and managed to get the car to move in 1st by adding 1L of fluid to the box and touching the throttle, but need to stop the leak before i do anything else. Seems like i will be using alott of threaded inserts / helicoils getting things tight.

Engine oil level is fine. Looks clean. Tranny fluid level is emptying itself. The 3 bolts in line with the leak feel like theyre bordeline stripped. Someone cant use a torque wrench, or has used an impact gun.

Where do you reckon this leak is coming from ?

Any help happily received!
Attachments
Drivers side driveshaft
Drivers side driveshaft
IMG_1503.jpeg (480.61 KiB) Viewed 419 times
Driveshaft bolt
Driveshaft bolt
IMG_1504.jpeg (808.63 KiB) Viewed 419 times
In park with engine running
In park with engine running
IMG_1505.jpeg (572.25 KiB) Viewed 419 times

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Krons
Posts: 1077
Joined: 9 January 2022
Year and Model: 08S60 05XC90 02S60
Location: Des Moines, IA
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Post by Krons »

The T6 transmission has a reputation for being weak. I’d carefully consider a rebuilt transmission vs the eBay option. I’d hate to swap them and 3000 miles later be in it again.

On the leak, is the housing cracked? I’d wonder if you pull that middle bolt if it would leak further, uncertain if that bolt needs to be sealed.
08 S602.5T/05 XC902.5T/02 S602.4T
08 C702.5T (sold)
05 S402.4i (RIP, timing belt failure)
The non-Swedes:
25 Mazda MX-5 / 17 Frontier Pro-4X / 17 Ford Focus
17 R1200GS / 15 Versys 1000 / 11 DR-Z400S / 07 R1200GSA

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