2013 XC60 T6 Axle is stuck

[scot850]

I have been asked for help by a friend with this car. He had it at a Volvo specialist and they said he needed a new LHF (AWD car) axle. I have since found it was replaced about 60,000 miles ago with an aftermarket one. The issue is they can't get it out of the transmission and have now effectively destroyed the axle so it could not be re-built on the car.

I have heard of axles being stuck in the older P80/P2 models I am more familiar with, but usually they eventually come out. My mechanic friend says he has heard of this happening on XC60's before but not common.

The repair shop has basically washed their hands of the car and say that to fix it they will have to replace the whole transmission. They have a low mileage engine and trans but won't separate them and have said they will install it all for $4500 US on a car with close to 190,000 miles on it.

I hate aftermarket axles, and in particular the split retaining rings they supply as they are usually the wrong profile. I only fit new Volvo rings even on aftermarket axles.

Has anyone had this issue and found a way to fix without swapping the trans out?

My ex-Volvo mechanic buddy has offered to do a trans swap and so I have to see if we can find a suitable trans. Volvo info seems really conflicted on what else has the same trans. I have seen them listing P3 XC70's both turbo and non-turbo with the i6 3.2 and the turbo and non turbo XC60's with the 3.2 and 3.0 turbo engines. Years covered 2011-14 some say 15 and 16 with the T5 motor as well.

My old version of Vida only list the trans for the XC60 turbo 2011-14 as suitable. Any one know for sure what is correct?

I hate to fix jobs where other 'professionals' have been in there. In this case it is likely they have hammered the axle so hard it will now never come out. I have thought about having a go, . My buddy the mechanic is on vacation for 3 weeks and not having a spare correct trans is also a concern. There is of course a very slim chance I can get the axle out but if I don't then I am stuck with the car and I don't have the space.

Any help appreciated as I have no experience on XC60's or P3 XC70's.

Thanks,

Neil.

[Krons]

I’ve heard gravity sometimes helps, on install to have the split in the C clip facing down. So in your case if it isn’t going rotate 45° and try again, then repeat.

My S60 was a bit stubborn coming out, I used two pry bars at once to spread the load—wider the pry bar the better as to not risk cracking the transmission case. One of my pry bars was the flat type used for pulling nails out of boards.

[scot850]

I am note working on the car myself. I don't have storage space for another car otherwise I'd get the owner to have the car dropped off and try to remove it using a method like you are mentioning. The likelihood of success is really low as:

1) It is an aftermarket axle and who knows how it was fitted (was it hammered in damaging the C-clip) and it is an aftermarket C-clip!
2) The Volvo independent shop, who I believe fitted the aftermarket axle, Have really hammered on the old axle probably damaging the outer side of the clip. The aftermarket ones are often square sided which is usually the issue in fitting and removing.

My mechanic buddy is away on vacation for 3 weeks. The owner has accepted another trans and axle will be needed. We may also install new axle and AWD output seals as well as the RMS while in there. I believe he plans to order the Ebay unit with the 6 months warranty in the next couple of days as the delivery from wherever is about 3-5 weeks!

I will get the car delivered as soon as my buddy is available to do the swap and have a go at removing the axle myself. Can't make it much worse than it is. Prices of used trans are crazy. My usual friends out on Vancouver Island (never had a bad part) wanted $2000 + $300 shipping and 12% tax (CDN) for a 98,000 mile 2012 T6 trans. An Ebay one is $1500 (CDN) with tax and free shipping with 6 months tax again for a 2012 with about 5k miles less on it.

Neil.