Angle / Bevel gear wrecked - looking for advice Topic is solved

[scot850]

Love the ghetto fix. Simple but effective!

Neil.

[jvl]

Thanks ecbsykes for the pictures! As you say, looks ghetto but that doesn't matter as long as it works, right?

As I appreciate having the AWD system fully functioning and (used) parts are hard to find, I'm now looking at prices for an overhaul of the angle gear. Brought the car in to my indy this morning, and hope they'll come up with a reasonable price.

Keep you posted.....!

Joost

[caz2773]

Sorry to hear that if u take the angle gear/ bevel gear case and split it u may be able to bolt the half case so it holds the sleeve in place and not use the clamps

[jvl]

It seems like Neil was right! Writing this up for other people for future reference:
My indy has been very busy so I didn't hear much over the past few weeks up until last weekend; they diagnosed the sleeve that connects the transmission to the angle gear was worn out on the angle-gear side, as has the splined axis in the angle gear itself.
I would like to have gone the 'proper way' and get the entire angle gear overhauled and to throw in a new sleeve, but my indy's contacts all said they couldn't/wouldn't do it. Independent overhaulers I contacted myself didn't see it happening either...
Searching for used angle gears was also not succesful (the '98-'00 V70XC is starting to go extinct in The Netherlands...), so I started brainstorming to find another, more custom, solution. (Plug)welding was one of the first things that came to mind. Not being a specialist myself, I started googling and found that people have welded up their sleeves before, and I was lucky enough to find a topic about it written by JanHargis over at Swedespeed: http://forums.swedespeed.com/showthread ... VER-again!!

Throughout my quest I've also found these videos by Robert DIY to be really helpful, one is about the the sleeve (and its part number: 31256008), the other is about the angle gear in general:

https://youtu.be/pZXRLTxdWUc
https://youtu.be/7REj85dqUIs

The garage gave me a call this afternoon saying that the last contacts they've reached out to for a used angle gear couldn't deliver so it seems like there's no other way out than welding the sleeve up... I know it's a rather dodgy fix, but being unable to use this angle gear as-is or have it overhauled, I guess the best option is to just try.
They'll start tomorrow, I've also asked them to check the tranny seals and visco really thoroughly while they're at it and hope all problems will be solved soon now!
Question: anyone know the proper torque values and procedure for visco-testing?

Will keep you posted and let you know if this solution is what you wanna be doing in the future as well!

Joost

[jvl]

GOOD NEWS!
The angle gear sleeve was welded up very nicely by my local garage and the car is driving great!
It took them 9 hours in total; because the angle gear with sleeve welded was hard to fit back in. They disconnected the tranny oil cooler and shifted the entire block a few cm's using a jack. This was time consuming but the only way to go, since I couldn't get my hands on a good used angle gear.
The viscous coupling was also tested and is - as far as can be seen - performing well.
The only problem that has arisen is that, I guess because the battery has been disconnected for a couple of weeks, my keyfob has stopped working.... Volvo's never bore you!

Thanks all, for all of your tips and advice. Hope this topic helps someone else in the future.

Joost

[oragex]

Great update.