AWD Problem

[cn90]

Re Angle Gear Sleeve.

I talked to some local Volvo mechanics, the Volvo sleeve is basically unchanged from the factory one. Not sure why they don't upgrade it.
- It always strips on the Angle Gear side, not on the Transmission side.
- It has an average lifespan of 80K-100K etc.
- So if you replace your sleeve, soon or later it will go out again. Not a big deal if you want to keep you car as FWD only.

After I looked at the stripped sleeve at the mechanic shop, I noticed the following:
- The Transmission side of the sleeve looks good, the Angle Gear side is rusted and stripped.
- The Right Shaft Axle passes right through the sleeve, through the smaller seal, into the Transmission itself.
- The Sleeve has its own seal (the larger seal).
- The Transmission side of the sleeve is bathed in ATF ---> no rust.
- A thought from me: if you replace the sleeve ---> good idea to grease it well on the Angle Gear side to prevent rust, and potentially another sleeve failure. In fact, the grease is included in the kit.

So, if people remove the Angle Gear to convert the car to FWD, they must keep the Sleeve in place, otherwise, ATF will leak out.


Some photos:

- If you buy the kit, you get small and large seals, grease, and 5 bolts (if you decide to reseal the Angle Gear 2 halves).

- Note the locations of small and large seals and their relationship to the sleeve and axle.

[precopster]

I'm wonderimg if the grease supplied is up to the task of handling multiple warmp up and cool down cycles and becomes dry, flakes right out of that enclosure and causes the issue.

Castrol and others produce high quality disc brake grease which is for front wheel bearings. It was an awfully smelly blue compound that I had for years then one day threw it out. (big clean up in the workshop) I used to repack printer bearings using it. It always lasted well beyond my expectaions.

[cn90]

For those w/o access to a shop lift...

I have an idea re diagnosing Angle Gear Sleeve (driveshaft will not spin) vs Haldex not engaging.

- In the winter, if you have a slight slope with snow/ice, drive up the hill while having someone observing the wheels. If all 4 wheels spin like crazy, then AWD works. If only the FRONT wheels spin, then you have 2 possibilities:
a. Angle Gear Sleeve vs
b. Haldex

- I have not tried this but this is my idea: get your smartphone or camera, set it in video mode.
- Place the camera on top of a cardboard to avoid damage to camera.
- Place camera in such a way the it records the movement of the driveshaft (which may be blocked by the exhaust). Best is to place the camera on the ground near the Angle Gear, pointing upward to capture the driveshaft movement.
- Put car in "D" and roll slowly forward.

Now review the video, if the AG Sleeve is stripped, the driveshaft will not rotate.
If the driveshaft rotates, then the problem is with Haldex.

What do you guys think about this camera trick?

[jaces_dad]

Just to clarify, if the drive shaft turns freely by hand when in park then my problem is the the sleeve presumably and not the Haldex, is this correct?

[cn90]

Just to clarify, if the drive shaft turns freely by hand when in park then my problem is the the sleeve presumably and not the Haldex, is this correct?

Interesting idea!

I think you are correct b/c during vehicle motion, the driveshaft "free-wheels", i.e., not connected to the rear diff until told to do so by the Haldex.

Anyway, I may be wrong...

[cn90]

Bringing back an old thread, hope to have some good input.
- I know my angle gear sleeve is kaput: heard grinding noise when backing out of the garage, on the snow: only the Front wheels spin.
So my 2005 XC90 AWD now runs as FWD vehicle. I have snow tires on, so no biggy.
- I probably save some fuel mileage as this is a FWD vehicle.

Now my curiosity kicks in:

1. The Angle Gear Sleeve: what is the exact reason the splines strip off: it is bad metal or rust?
Mine stripped under no load at all (backing out of the garage into my driveway).

2. The new part sold by Volvo vs VIVA performance: is there a difference in quality?

3. So now the $1M question: should I even fix this, even though there is a chance the new sleeve will strip again? In other words, an "exercise in futility"...

[gstallons]

From the photos cn90 has posted , it appears that it should have had some type of grease in the coupling to keep the rust from eating the splines up and destroying things. I would suggest anti-seize the splines when reassembling ....

[germonds]

I know this is a DYI forum but with no garage and parking in public parking so if anyne knows a good mechanic who works on the angle gear in and around NYC area for 2005 xc90, I'm planning to get a used part. Dealer wont work with outside parts.

Thanks

[Gig]

All I need is the trick to getting the front Angle Gear, Haldex Unit, differential or whatever you term this demon of a mess calledd a part off of its perch at the front end of the drive shaft, propshaft, WITHOUT removing the exhaust system, which is rust-welded to itself front to rear. Can anybody tell me how to do that? I am holding about 13 various sized metric bolts,, yet it still clings to its throne. I discovered a very bright kid on You Tube last night who has re-engineered the Volvo abortion, from a billet of alloy aluminum. His design is simple, strong, and much less of a time-bomb-compared to the Volvo finger trap. I have been a professional aircraft and race mechanic since 1962, but I have never been this stumped!!! Please, somebody save me.

[precopster]

My recollection was that there are 10 bolts on the angle gear.

Two of them were so hidden and difficult to turn that I was lucky to get about 10 degrees of rotation on them.

There may be a hidden one?