AWD Problem

netasp · Post by **netasp** » 06 Jul 2012, 12:39

Hi guys,

My 2004 XC90 went for diagnostics and the following came back:

"Angle gear has a heavy grinding noise, Gearings in angle gear are damaged causing AWD to not function and adding stress on transmission. Recommendation is to replace the Angle Gear + Sleeve"

Total cost is $1980 Angle Gear Part & $140 for the Sleeve part + 5 hours labour (~500)

My car is not leaking oil or anything like that. Is he out to lunch for the pricing?

Thanks

Post by **jimmy57** » 06 Jul 2012, 13:41

Get another shop to look and give second opinion. The labor is a bit high.
The front CV joint on the driveshaft to rear should be packed with grease to assure that joint doesn't fail. The grease in it will dry out since the catalytic converter is so close.

netasp · Post by **netasp** » 06 Jul 2012, 13:49

My CV joints are good, nothing wrong with them, but apparently the Angle Gear is another animal

500 ==> 4 hours @ 110 + Tax

Post by **JDS60R** » 06 Jul 2012, 13:58

I think Jimmy is referring to the cv joint bolted to the rear output shaft of the Bevel/Angle gear. if it hasn't been repacked since new - it needs it.

Post by **jimmy57** » 06 Jul 2012, 16:40

I'm not really doubting their diagnosis so much. Angle gears can and do fail. The oil gets hot and they lose oil to evaporation.
The CV joint on the front of the rear driveshaft is not a maybe on AWD models, it is a when. Lubing it before the grease turns into something resembling melted crayons will save it. The shafts are $500 US plus additional shipping and handling to CAN for a rebuilt non-oem and $1000 or more for OEM new. The front CV joint is available as a spare part from Volvo for some but the joint is north of $200 plus labor. tapping the end cap off while angle gear is out w/o removing the shaft to dig a bit off the old stuff out with a pocket screwdriver and pack it with a $7 tube of CV grease should be $50 if the shop doesn't like you.
Volvo has a reseal repair for angle gears that they list a labor time of less than 3 hours for the r&r and the dismantling, cleaning, some filing by hand, and re-assembling.

netasp · Post by **netasp** » 06 Jul 2012, 16:56

I talked to a third party shop and he recommended that I buy the whole transfer case instead (used) as it will be much better than opening the case and replacing the Angle Gear and the sleeve.

I found a site just for used parts, they are asking $666 for the whole transfer case, age of it 80K. What would you do?
here is the link to the site:
http://www.usedpartx.com/usedparts-stor ... &seq_num=2

Post by **jimmy57** » 06 Jul 2012, 17:07

The sleeve is the internally splined collar that slips onto the splined shaft out of trans and the splined shaft out of angle gear.
I would think the $1980 they quoted was for a new complete angle gear assembly from Volvo.
That sounds a like a decent price for a good used unit. I would still recommend the connector collar be replaced.
The angle gear needs to have new synthetic 75W140 gear oil put in it when it is installed.

netasp · Post by **netasp** » 06 Jul 2012, 17:23

Thank you jimmy for your help. I think I would more leaning toward either let the dealer replace the whole Angle Gear OR let a third party shop do the whole Transfer Case replacement. I don't think an independent mechanic would be able to do the Angle Gear replacement unless he is really good and those are hard to find these days.

thx

Post by **jimmy57** » 06 Jul 2012, 19:36

I think there is a terminology issue here.
Angle gear is a bevel gear is a transfer case. Different names for the same 90 degree gearbox that bolts to the sideways oriented transmission and turns the power flow 90 degrees so the driveshaft points to the rear axle with the AWD control system on the front of rear differential.
The angle gear units do not have gear parts available from Volvo as spare parts. The bearings and seals are serviced but not the actual gears. One of the gears is mounted to a spindle using a specialized adhesive and is pressed on. The press fit makes that spindle not usable to properly retain a new gear pressed onto it.
A transmission repair shop that deals with Volvos would have a lot of experience with these as they have to be removed and re-installed to do transmission repairs. You can't remove the transmission without removing the angle gear unit first.

netasp · Post by **netasp** » 06 Jul 2012, 20:44

Jimmy,

can you look at the pictures? if I understand you correctly, the whole thing in picture should be the Angle Gear Assembly?

I was given by the dealer Part # 9495034 And Part # 36000340 that I need to buy.

You sound an expert on these things and I am trying to see exactly what I am looking for before buying it used

thanks