AWD Transmission: DIY AWD repair instructions - Unable to reply to that post?

[timh30]

Hi - sorry for creating a new thread, but I'm unable to post in the original one.

As I need to tackle replacing the splined sleeve, I have a few question for the original poster:

Do you have the part number of the splined sleeve kit ?

You said you cut a notch and used a crowbar to lever out - I've seen others who have drilled a hole through both sides of the sleeve and used a puller to get it out - do you think there is room to do that on the xc90 ?

Cheers,
Tim.

[BestGear]

Hi - just fyi - I think once threads are in the articles section, they are there for reference only, ie not for general chatter or discussion.

I did ask the OP for part number of kit, but it was not available and he suggested you speak to Volvo with your VIN or reg number.

David

[D5Gill]

I tried to get back into the post to make some amendments and correct some typos but couldnt.

To answer your question, Volvo pn for the kit: V30787988 £80.50 +vat
I wouldnt suggest you use it to order the spline for your car. This part number was specific to my car (2005 D5 163bhp Geartronic). The PN might be different for your car. You sould really go in armed with the VIN or Reg.

I saw the posts with images that you refer to with the drilled holes. If you have a good drill and can hold it steady to go through hardened steel, then go for it. This seemed too much hassle for me as the sleeve was stuck in the transmission. I initially cut a shallow notch with an angle grinder and walked it off with a pry about an inch. (see image) This got harder and harder, so I gave up and cut right through the first notch and hooked on my slide hammer. I wish I had done this first. By far the easiest and quickest option.
No heat or WD40 was used to remove the spline. I'll be damned if you can get a puller onto the transmission without removing it.

I would add to my original post that I replaced the bevel gear fluid. It drained 700ml and there is a clear notch marked on the unit as a maximum. The replacement bolts in the kit are 13mm headed as opposed to the 14mm one removed.

I can also report that all my wheelspin has disappeared. I have tested the car up in the air and all four wheels rotate when in drive.
Reassembly took just 2 hours in total because I knew what I was doing. The disassembly took longer because I was working off the cuff and without instruction
I am happy to answer your questions as you tackle this job

[timh30]

Many thanks for the additional info D5gill. I'll probably be tackling this sometime next week, so thanks for the offer of advice.

[400-ascona]

Not sure if the Nottingham dealer was correct, but they told me that the T6 doesn't have the splined sleeve, and so doesn't have the problem. Can anyone confirm this?

[owenfackrell]

Originally Posted by 400-ascona

Not sure if the Nottingham dealer was correct, but they told me that the T6 doesn't have the splined sleeve, and so doesn't have the problem. Can anyone confirm this?

According to my copy of vardis the T6 has a chain drive arrangement instead of the sleeve.

[REDSHEEPRIDD]

[QUOTE=D5Gill;767899]

I can also report that all my wheelspin has disappeared. I have tested the car up in the air and all four wheels rotate when in drive.


From a previous thread - many, like myself experience slight wheel spin away from junctions (especially when the wheels are turned) before AWD is engaged - must say mine feels like more than 1/7th of wheel turn as stated, but I definately still have AWD - but could this be a sign of impending failure?
When you say NO wheelspin - is this No?

Can you also confirm if yours did 185K miles on original sleeve before failure?