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2002 S60 AWD driveshaft removal help

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive P2 platform cars sold as model years 2001-2007 (North American market year designations).

2001 - 2007 V70
2001 - 2004 V70 XC (Cross Country)
2004 - 2007 XC70 (Cross Country)
2001 - 2009 S60
2003 - 2007 S60 R
2004 - 2007 V70 R

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zmf
Posts: 9
Joined: 10 July 2014
Year and Model: 2002 S60, 2001 XC70
Location: BOS

2002 S60 AWD driveshaft removal help

Post by zmf »

So, I haven't had AWD for a while - not sure exactly how long, but it was quite evident this past winter. From what I've read, not really worth fixing (this car is also on its last legs, it seems).

Anyway, on Monday the center support for the driveshaft (fore-aft) rusted apart, dropping the driveshaft onto my exhaust. I drove 30 miles before I could figure out what that awful sound was. It sounded like the exhaust was dragging, but it wasn't. Should have figured it out sooner, but whatever.

I just decided to remove it. I've read here and elsewhere that it's pretty straightforward, but I'm wondering if it's different on my car (those were 98s I think). I've removed the 6 bolts each front and rear. I've smacked it with a ballpeen hammer. For almost an hour now. It's not coming off. I can slide it back and forth a little bit, and the front cap on the rear one is loose - I can stick a big flathead in there and get it all greasy, but it won't drop.

My arms and head are damn sore, and I'm looking for ideas. I figure if I try to drive it a little in the driveway just to loosen it up, all I'll end up doing is ripping off my O2 sensor or something equally stupid. So, I'm looking for better ideas, or experience, or something.

Thanks.
current: 2002 S60 AWD, 2001 XC70 OSD, 2001 2.5RS
ovlov yard: 89 745, 88 744, 84 245T, 76 242

vtl
Posts: 4727
Joined: 16 August 2012
Year and Model: 2005 XC70
Location: Boston
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Post by vtl »

With the support bearing carriage off it should drop down without problems. If exhaust does not allow center of the shaft to lower, remove all hangers and drop the exhaust.

zmf
Posts: 9
Joined: 10 July 2014
Year and Model: 2002 S60, 2001 XC70
Location: BOS

Post by zmf »

The rear one is reasonably accessible. After pounding on it for a bit, I could that it was starting to work its way out. I got the MAPP torch, and <2 minutes of heating all around, it just popped right off.

I'm still having no such luck with the front one. It's harder to get at, but after days of hammering and soaking with PBlaster, 4 long heating cycles with the MAPP torch, and a couple rounds with the air hammer, it's not budging. Oh, almost forgot the come along. I hooked it up to the rear to help pull it out, but so far all I've done is mangle the rear flange. More heating, soaking, pounding, and still nothing. I can't hit it directly with a hammer, so it's all either through a screw driver or a pry bar.

I'm thinking now I need to put it in drive with a big pry bar through the U joint or a pipe wrench on the prop shaft or something similar. It just seems like the kind of thing that can go wrong rather quickly. Rotating it out is also probably not the best way to break the bond, but I'm running out of options.

I do think I'll be able to slide it out to the rear without having to do anything to the exhaust, but we'll see.
current: 2002 S60 AWD, 2001 XC70 OSD, 2001 2.5RS
ovlov yard: 89 745, 88 744, 84 245T, 76 242

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