IPD sale XeMODeX - Experts in Volvo Electronics
Did you know? 🤔
Logged in users can get email notification of topic replies Log in or register (free).
Amazon Link Buy your stuff using this and it helps MVS!

2004 XC70 occasional shudder under part throttle

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive "P2" platform cars.

2001 - 2007 V70
2004 - 2007 V70 R
2001 - 2007 XC-70
2001 - 2009 S60
2003 - 2007 S60 R

User avatar
greg850r
Posts: 236
Joined: Thu May 03, 2012 5:06 pm
Year and Model: a long list
Location: Mo
Has thanked: 4 times
Been thanked: 8 times
United States of America
greg850r

Re: 2004 XC70 occasional shudder under part throttle

Post by greg850r » Thu Oct 03, 2019 7:51 pm

The leak is more on the right, it is dry underneath on the left and wet from right to center.

I too surmised the pump had enough fluid, so now I wonder if it is bad. I'll check it Saturday as I have other obligations tomorrow. The fluid was thin but dark and I don't think it is contaminated with gear oil. It all drained out the pump area but before I removed the fill plug only a tiny amount. After I took the fill plug out a small bead of fluid ran out the pump area for a long (hour?) time. It looked clear to yellow draining but the container of all of it looks darker. I cut open a quart oil container and it has 460ml of fluid in it now that I deposited what I sucked out with a syringe.

The fluid on the diff housing and bottom of the spare tire well does not appear to be gear oil. I have not pulled the gear oil fill plug on the back yet but will to check level and color when I get back to working on it.

The pics I found had the 2 fill plugs (pump and gear oil) about 2 inches apart on the driver's side of the housing toward the front by the pump controller. Mine is not like that. The pump oil fill plug is there, but the gear oil plug is on the rear near the outside edge of the ring gear judging by the shape of the casting. One more thing that is not like the pics I have found is the cover screw on the pump. All the posts, videos, etc. I have seen show 2 screws on the pump cover and I only have 1 on mine. I quit trying to break it loose just a hair shy of stripping out the drive splines and was unsuccessful using a small vice grips on the outside edge to turn it so alas, was not able to look at the brushes.
The driveshaft is back in now but not the exhaust. Hope I don't have to pull it again to change the pump, my wife wants her car back. Could I have checked the pump with 12v on the bench? I had a shop teacher in high school who warned of what brute force and bloody ignorance could get you so I was reluctant to do so not knowing if it was powered by a reduced voltage or not.


05 Cross Country wagon
99 C70 Convertible
96 850R wagon
96 850T wagon
96 850 GLT 5spd N/A sedan
97 850R 5spd sedan
66 GTO 421SD 4spd
67 GTO 455 T400
02 Powerstroke 4x4
85 Yota 4x4
24' 454 Challenger
07 Softail Custom
02 Sportster Custom
Parts cars not included

User avatar
- Pete -
Posts: 192
Joined: Fri Dec 06, 2013 10:13 pm
Year and Model: 01, 04, 04, 04, 06 V
Location: Minnesota/Wisconsin
Has thanked: 20 times
Been thanked: 30 times
United States of America
- Pete -

Re: 2004 XC70 occasional shudder under part throttle

Post by - Pete - » Thu Oct 03, 2019 10:56 pm

From what I've experienced & read, yes, functional DEM pump is responsive to 12V so a bench test is simple. Pump rebuild kits w/bearings are cheap too, like $35 from Latvia IIRC. I've saved my old pumps (in the case I get the nerve to dissect them & attempt to revive them).

I've read where people have used a 9V battery to test function & have seen it operate successfully. 2 pin connector so obviously there's only a + and a - . I personally haven't done these miniscule tests. Just the "engine running, ear to pump" test, and the "are the rear wheels spinning while in forward gear?" (car in the air) test. I don't know what kind of load the pump sees when properly operating, but I wouldn't be surprised if a successful bench test could still prove rather useless compared to real world operation/demand for AWD ie the pump being installed w/oil in cavity & powered by ECM.

I'm still astonished you had to remove the exhaust. sucks, but time is valuable & cats can get skinned a few ways.

My pumps have all had just the 1 screw for the cover. I believe it is a teeny tiny torx. I’ve never gone down the rabbit hole though.

Yes, AOC fluid will be runny and gross looking in a clear receptacle/container. I think mine smelled pretty bad too. And I had changed it a couple times prior to pump replacement. Real black & particulate laden towards the end of the run of fluid.

I've also seen the photos of the AOC/final drive filler plugs just 2" apart. I own 4 of these cars (01-06) and not a single one of them is in this configuration.

Maybe get a couple bestest most gooder pictures of the leak/area. Those pics you posted help to show you have a leak, but don’t really tell a whole lot else (to me). Based on what you collected (440-460ml) from the AOC, most likely an AOC fluid leak. I believe its capacity is ~800ML, but don’t quote me. Regardless of capacity, proper fill procedure is fill to the point it drips from filler hole, then evacuate 100ml.

I'd suck out the final drive gear oil & see what ya got for quantity.


2001 V70XC 142k
2004 V70 AWD 134k
2004 V70R M66 142k
2004 XC70 278k
2006 XC70 155k

User avatar
greg850r
Posts: 236
Joined: Thu May 03, 2012 5:06 pm
Year and Model: a long list
Location: Mo
Has thanked: 4 times
Been thanked: 8 times
United States of America
greg850r

Re: 2004 XC70 occasional shudder under part throttle

Post by greg850r » Sat Oct 05, 2019 12:35 pm

- Pete - wrote:
Thu Oct 03, 2019 10:56 pm
Maybe get a couple bestest most gooder pictures of the leak/area. Those pics you posted help to show you have a leak, but don’t really tell a whole lot else (to me). Based on what you collected (440-460ml) from the AOC, most likely an AOC fluid leak. I believe its capacity is ~800ML, but don’t quote me. Regardless of capacity, proper fill procedure is fill to the point it drips from filler hole, then evacuate 100ml.

I'd suck out the final drive gear oil & see what ya got for quantity.
Thanks Pete, I'm looking at it in person and it does not tell me much beyond there is a leak either. I put 600ml in before it filled to bottom of hole. Then I put the plug in and put 12V to the pump and ran it a bit. I reversed the wires once and could tell when it ran backwards because it spun freely. Hooked up correctly and I could tell when the pump slowed a little due to the resistance of pumping fluid. After I ran the pump I removed the plug and added 30ml more before it started to run out again. I'm going to search around a bit to make sure about removing 100ml before I do. I'll go after the gear oil when this part is all finished as I only have one syringe and would rather a tiny bit of AOC fluid get in the gear oil than the other way around.
Should I drive test it before going after a level correction to be sure there's no air where fluid should be making it seem full when it isn't?


05 Cross Country wagon
99 C70 Convertible
96 850R wagon
96 850T wagon
96 850 GLT 5spd N/A sedan
97 850R 5spd sedan
66 GTO 421SD 4spd
67 GTO 455 T400
02 Powerstroke 4x4
85 Yota 4x4
24' 454 Challenger
07 Softail Custom
02 Sportster Custom
Parts cars not included

User avatar
greg850r
Posts: 236
Joined: Thu May 03, 2012 5:06 pm
Year and Model: a long list
Location: Mo
Has thanked: 4 times
Been thanked: 8 times
United States of America
greg850r

Re: 2004 XC70 occasional shudder under part throttle

Post by greg850r » Sat Oct 05, 2019 2:59 pm

I opened the rear diff and it was dangerously low. In retrospect I must be wrong about the oil that leaked not being from the differential. Not having anything to put in it I had to improvise. I had this on the shelf so I used it.
mercruiser.jpg
Don't laugh, some oil is better than no oil and this will be good enough to drive it a few miles and then flush. It took 400 ml so I think it had enough in it to prevent failure, but I am glad I saw it and topped it off. I have some Amsoil severe duty 75-90 on order for this and the front angle gear, but it isn't here yet.

The front angle gear oil looks amazingly clean on the stick. I bent a hangar wire 90 degrees and the level was as shown. About 1 1/4 inches below the plug hole. I used an angle pick to mark the oil level in case the picture didn't show it.
rear diff.jpg
You do not have the required permissions to view the files attached to this post.


05 Cross Country wagon
99 C70 Convertible
96 850R wagon
96 850T wagon
96 850 GLT 5spd N/A sedan
97 850R 5spd sedan
66 GTO 421SD 4spd
67 GTO 455 T400
02 Powerstroke 4x4
85 Yota 4x4
24' 454 Challenger
07 Softail Custom
02 Sportster Custom
Parts cars not included

User avatar
- Pete -
Posts: 192
Joined: Fri Dec 06, 2013 10:13 pm
Year and Model: 01, 04, 04, 04, 06 V
Location: Minnesota/Wisconsin
Has thanked: 20 times
Been thanked: 30 times
United States of America
- Pete -

Re: 2004 XC70 occasional shudder under part throttle

Post by - Pete - » Sat Oct 05, 2019 3:18 pm

Did you change the Haldex Filter?

Yeah I would definitely drive it around a little while. Both to recheck oil level & also see if AWD Is working. Might have been the placebo effect with our 04XC, but the original pump did seem to work better after I cleaned it, changed filter & added new AOC oil. Alas the pump truly pooped the bed not but a few miles later so had to tear it all apart again. I’ve gotten really good at removing driveshafts.

That gear oil will be better than none. I’ve seen shows where in Africa/Australia (can’t remember which) when trucks blow axle seals hundreds of KM from anywhere they mash bananas up in there for lubrication & cram the peel in last for a “seal”.

If final drive was truly low, it must be coming out the passenger output seal. It’s tough to snake your tube in the rear diff so fully suck it all out. I’ve had a couple nervous moments where I thought the tube was surely pinched in the gears. A big “whew” when it comes out all the way.


2001 V70XC 142k
2004 V70 AWD 134k
2004 V70R M66 142k
2004 XC70 278k
2006 XC70 155k

User avatar
greg850r
Posts: 236
Joined: Thu May 03, 2012 5:06 pm
Year and Model: a long list
Location: Mo
Has thanked: 4 times
Been thanked: 8 times
United States of America
greg850r

Re: 2004 XC70 occasional shudder under part throttle

Post by greg850r » Sat Oct 05, 2019 4:43 pm

Yes, I changed the filter. The old one was very dark. I also did a drain and fill with 3.5 quarts of recommended transmission fluid and tested it in the air. Still no movement at rear wheels. Slid under and Haldex pump not running. I'm starting to suspect a loose connection at the box back there since it runs perfect when 12v is applied.

Update: I did some more research, got back under the car with it running in gear and discovered that the prop shaft to the rear is not turning at all. I guess I started at the wrong end and should be looking at the angle gear mechanism.
Sigh; time to read some more.
Last edited by greg850r on Sat Oct 05, 2019 9:33 pm, edited 1 time in total.


05 Cross Country wagon
99 C70 Convertible
96 850R wagon
96 850T wagon
96 850 GLT 5spd N/A sedan
97 850R 5spd sedan
66 GTO 421SD 4spd
67 GTO 455 T400
02 Powerstroke 4x4
85 Yota 4x4
24' 454 Challenger
07 Softail Custom
02 Sportster Custom
Parts cars not included

User avatar
greg850r
Posts: 236
Joined: Thu May 03, 2012 5:06 pm
Year and Model: a long list
Location: Mo
Has thanked: 4 times
Been thanked: 8 times
United States of America
greg850r

Re: 2004 XC70 occasional shudder under part throttle

Post by greg850r » Sat Oct 05, 2019 9:26 pm

Well I've read enough to know this will not be fun. I'm going to sleep on it and probably start a new thread tomorrow, and link it here, about angle gear sleeve removal.
collar.jpg
The red ring in the picture indicates what I shall set up a puller to push on. It does not look encouraging;
viewtopic.php?f=9&t=71794&p=378227&hili ... al#p378227
https://forums.swedespeed.com/showthrea ... ar-Splines
Anyone else who has removed one of these please chime in. It looks like I will be shopping for an appropriate puller and then trying to cut holes in this sleeve for a puller to grab, because there is nothing. I would comment about the thought processes of whomever engineered this marvel but I find the English language woefully inadequate for the task.
The part is here: https://www.fcpeuro.com/products/volvo- ... 0787988#qa
You do not have the required permissions to view the files attached to this post.


05 Cross Country wagon
99 C70 Convertible
96 850R wagon
96 850T wagon
96 850 GLT 5spd N/A sedan
97 850R 5spd sedan
66 GTO 421SD 4spd
67 GTO 455 T400
02 Powerstroke 4x4
85 Yota 4x4
24' 454 Challenger
07 Softail Custom
02 Sportster Custom
Parts cars not included

User avatar
- Pete -
Posts: 192
Joined: Fri Dec 06, 2013 10:13 pm
Year and Model: 01, 04, 04, 04, 06 V
Location: Minnesota/Wisconsin
Has thanked: 20 times
Been thanked: 30 times
United States of America
- Pete -

Re: 2004 XC70 occasional shudder under part throttle

Post by - Pete - » Sat Oct 05, 2019 10:33 pm

Uh oh.

How many miles are you at on this XC?

Well if that's the case it's basically down to your collar sleeve being shot and/or the input splines on the BG are eaten away. Seems they eat each other out & replacing both collar sleeve AND BG is the only real (long-term?) fix. :? I really hope that's not the case for you. When you have the driveshaft out it's a great time to take the bevel gear off the trans to inspect the collar sleeve/BG input splines etc... You'll know if the collar sleeve/BG input splines are done for. There will be cakes & clumps of rusty shredded steel surrounding both & the splines themselves will be worn down to sharpened remnants, if they are even there at all that is.

Did you suck the gear oil out of the bevel gear? There is a chance it failed internally, but that's pretty improbable.

Funny, I just got a collar sleeve. In my area bevel gears range from $500-750 dependent on mileage & wear. Collar sleeves are pretty inexpensive. Hopefully you're not in for a collar sleeve, BG, Haldex pump & other associated AWD items.

I found a guy/place in the Netherlands (I think) that rebuilds bevel gears. I never did arrive at anything or final cost + shipping for one of his units but I sure wish there was one of him over here. Henk Brunekreef. All I've seen is one video & their website. Could be a sham, sure looks nice though.

You said your pump wasn't running also though. Obviously if the driveshaft isn't spinning that's no good. But your pump still should be running. Did you blow compressed air up there around & into the sockets were the 2 Haldex plugs/receptacles mate up? I've had tiny stones lodge up there making it impossible to fully seat the plug/receptacles.


Edit: I see you found your culprit. Sorry, I tried to respond faster. Make damn sure your BG input splines are in good shape before just replacing the collar sleeve.

This guy makes it look pretty easy. This is how I plan to remove the collar sleeve, when my time comes.
Ye ol' collar de-wizard's sleeve is toast, so use the internal snap ring groove for your puller.




2001 V70XC 142k
2004 V70 AWD 134k
2004 V70R M66 142k
2004 XC70 278k
2006 XC70 155k

User avatar
greg850r
Posts: 236
Joined: Thu May 03, 2012 5:06 pm
Year and Model: a long list
Location: Mo
Has thanked: 4 times
Been thanked: 8 times
United States of America
greg850r

Re: 2004 XC70 occasional shudder under part throttle

Post by greg850r » Sat Oct 05, 2019 11:19 pm

135xxx. It does not look good.Splines are still there and the collar took most of the wear but I can see the ends of the splines on the gear looking taller at the end where they went past the collar splines. I won't know until I buy a collar and fit it if there is enough left to get me by for awhile. I don't know if that tool would even be an option with it still in the car though. I also doubt my local auto parts has one for rent. Any idea where to get it?
1.jpg
2.jpg
3.jpg
You do not have the required permissions to view the files attached to this post.


05 Cross Country wagon
99 C70 Convertible
96 850R wagon
96 850T wagon
96 850 GLT 5spd N/A sedan
97 850R 5spd sedan
66 GTO 421SD 4spd
67 GTO 455 T400
02 Powerstroke 4x4
85 Yota 4x4
24' 454 Challenger
07 Softail Custom
02 Sportster Custom
Parts cars not included

User avatar
- Pete -
Posts: 192
Joined: Fri Dec 06, 2013 10:13 pm
Year and Model: 01, 04, 04, 04, 06 V
Location: Minnesota/Wisconsin
Has thanked: 20 times
Been thanked: 30 times
United States of America
- Pete -

Re: 2004 XC70 occasional shudder under part throttle

Post by - Pete - » Sat Oct 05, 2019 11:31 pm

If the splines still have flats at the top on the BG input you could be ok for a while. With all the debris on there it's hard to tell from the pictures. If on the BG side they still have flats (the full length of the splines), just replace the collar sleeve. I think collar sleeves are about $115 or $120 for these XC's.

That seems like low mileage for collar sleeve spline's to give up. Wife have a heavy foot?

Our 280k mile 04 XC with original BG is still going. Not sure for how long though, the teeth are pretty sharp on both sides of the equation.

I'm not certain there is a rhyme or reason to why some fail earlier than others. What I do know is the metal on one side is crappy, fails, and that in turn causes the other side to also fail.

Collar sleeve is toast so no need to be careful with it. Worst case could weld a nut to a plate (that has a pre-drilled hole) over the end. Weld that nut plate to collar sleeve. Then slide hammer it out.

Ya might get enough bite on the snap ring groove with an internal puller setup.


2001 V70XC 142k
2004 V70 AWD 134k
2004 V70R M66 142k
2004 XC70 278k
2006 XC70 155k

Post Reply