Bevel gear and Collar Sleeve Welding project

[Blacklab467]

Almost a month ago I noticed that the AWD wasn't working anymore while maneuvering in an icy parking lot, also noticed a faint speed dependant noise on coasting deceleration. With all four wheels in the air, I confirmed that the propshaft rotated freely independent of the transmission.........the bevel gear output shaft was not connected to the transmission output shaft.
Yesterday I removed the bevel gear and learned that my welded collar sleeve had spun on the bevel gear input splines. In summary, the three tig welds had let go. They had held successfully for 62000 kilometres.

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Fortunately, I had a brand new collar sleeve to install in the transmission to prevent the fluid from running out, I couldn't remove the broken welded collar from the angle gear as the welding residue kept the collar from sliding off.
A trip to the auto wreckers was fruitful and a excellent non-leaking angle gear was harvested from a low mileage (232000 km) 2002 XC 70. Note that the 2002 has a different length output flange and different flange diameter so I will have to order an '03 seal before installation and swap the flanges. I plan to change the fluid and install a drain plug also before installing the new angle gear and of course the seal and transferring my old flange onto the new gear. Meanwhile while I wait for parts I will run the car in FWD, without the angle gear or propshaft for a couple weeks.
I'm a little disappointed that my original welding project wasn't a permanent fix to the problem. I find it interesting that the welds held initially, only to fail 62000 kilometres down the road. I will run with a stock angle gear/ collar sleeve setup now but will endeavour to engineer a more robust solution to this problem in the future.

[scot850]

I wonder if the 'glue' Volvo used to use on P80 car front axle splines would work? It was designed to take oust the spline 'clicking' due to variances in tolerances of the hub bearing splines and the axle itself. It would be a devil to remove if you ever had to, but might be an option if it is still sold. I'll check later as I had a bottle of it that must be 20 years old!

Neil.

[vtl]

I wonder if the 'glue' Volvo used to use on P80 car front axle splines would work? It was designed to take oust the spline 'clicking' due to variances in tolerances of the hub bearing splines and the axle itself. It would be a devil to remove if you ever had to, but might be an option if it is still sold. I'll check later as I had a bottle of it that must be 20 years old!

Neil.

This joint needs to remain flexible.

[ggleavitt]

I am in the process of having an angle gear welded with a new collar. I own a 2008 XC90 V8 Sport (TF-80SC) and have gone through 2 of these so far in 10 years of ownership (my driving style coupled with a poor design). This thread has been of immeasurable help and the machinist is pretty clear on the approach thanks to the photos. Think he's going to drill into the input shaft a little to get some weld metal in the area below the splines but this is pretty much what we'll be doing.

I have a photo link for the job (on a V8 a whole bunch of stuff comes off to get the angle gear out): https://photos.app.goo.gl/PkDiEEkyfACWfnTx5 and a thread on Swedespeed describing the initial failure in 2016 to the most recent failure in January (XC90 GEN1 forum). I'll post back once the work is done, most likely in the XC90 forum.

Again, thanks for taking the time to describe this work with the visuals.

edit- add transmission