Angle gear collar sleeve and seal replacement Pictorial, 2003 XC70 automatic.

[RPG]

Hello,

I have a 2013 XC70, AWD with I believe a TF80-SC transmission, and had a leak coming between the angle gear box and output shaft.
After hours and hours of removing drive shaft and angle gear, I found that it was the output shaft seal(s) that had the leak.
I inspected the angle gear and zero visible leaks on that side that attaches to the output shaft.
I did replace all those seals on the angle gear.

I did install correctly new inner and outer seals with a new sleave.
All seals were Volvo parts.
I did take the time to reinstall correctly the gear box.


All was good after changing transmission fluid and gear box fluid.
Next day after 50 miles or so, its leaking from the same place (between the transmission output and gear box)

Is there a known issue of replacing both Inner and outer shaft seals and it still leaking?

[scot850]

It could be you rolled one of the seals. There are several tools Volvo has for doing this work. I helped a friend to replace his transmission in a 2013 XC60 with the TF80 trans. My ex-Volvo mechanic did the majority of the work with me for grunt work. Fortunately the owner paid for the tools we needed for the seal installs. The only one we didn't need was the one for the crank pulley as my friend had access to one.

If anyone out there has the 3D printing skills I would consider a loan of the tools I have for copying.

Neil.

[Blacklab467]

I'm not too familiar with the 2013, probably similar in design to the earlier ones. I will look into this. The output shaft seal is just a lip seal but of large diameter, I actually damaged the seal outside bore removing the old seal with a pick that caused a huge leak and had to go back in and JB Weld and sand the bore........perhaps you did the same? I think you may have no choice but to remove the propshaft and angle gear and figure out where its leaking from.
Use only Volvo branded seals on this job also, as I recall the big seal was about $67 from Volvo......I had to buy this one twice!

[RPG]

Thanks Blacklab467 and Scot850 for the reply.

I know I didn't roll the seals as installing the collar sleave it was easy to see them fully and to turn it when it was in neutral. And the inner seal it was easy to see that it fit over that inner post when the collar was in.
Just seems odd its leaking in the exact same spot. Thats why i thought there was some known issue and there is a seal just a couple thousands smaller i need to order instead of the standard.
And all the seal were Volvo seals, spared no expense on any of them.

Thanks, i'll keep you updated.

[Blacklab467]

Did you fit a new collar sleeve? On the earlier model like I've worked on the collar has a slight taper and if its not fully seated the seal could be riding on a smaller diameter area of the collar and leaking. Additionally you may elect to put some anaerobic sealant on the outside of the seal to ensure no leakage between the seal body and bore, it doesn't fit very tightly in the bore if memory serves correct.
The good news is that you can probably get that seal out without damaging it and reuse it.

[RPG]

I'm going to close my question with the final results.
Thanks to Blacklab467 for a clue into the plausible cause and fix. Gear Box Sleeve seal area.
My 2013 XC70 actually had two issues and i had to work these with for a total of 3 disassembles and reassemblies.
The second time i removed the Bevel Gear it was a seal i put in over the spline shaft that has a groove near the bottom that holds the shaft seal. I could tell this initially due to the clearer fluid leak (Bevel Gear oil), i rolled that seal.
I took some aluminum coil stock and made a sleeve to cover the splines of the bevel gear shaft that goes into the tranny, put grease on it and slid the new seal over and seated it, and pulled out the sleeve and that did the trick.
I checked the seal that the gear box sleeve slides into in the tranny, and with some Volvo printed maintenance procedure documents i got from Volvo, i checked the distance that it should go in to mate with that Collar taper on the sleeve.
After reassembly, tranny fluid still leaked.
So, after disassembly i decided to Double Seal the gear box sleeve. The width of the taper area is 5/8 inch, and each seal is just over 1/4 inch.
I determined where each seal would sit and tapped tapped tapped it in (Happy Gilmore)
Reassembled, but this time before i tightened the bolts, i installed the passenger drive shaft and installed everything for the wheel for alignment of the gear box sleeve and bevel gear. (no wiggle in the bevel gear when you do this)
NO LEAKS.
Talked to the Volvo mechanic i got the install procedure from, and he knows a couple of guys who had to do that on a couple of Volvo's. He can't figure out why that is, and my only answer to him was that when you position the bevel gear back in place, there is a minor amount of wiggle before you install the 5 bolts. And it could be that it's enough to possibly to angle the sleeve enough to push the seal more to one side allowing the potential to leak. He thought that might be maybe

Take away the couple of tricks i mentioned if anyone needs to do this.

Thanks,