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Rebuild transmission / uprated parts

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Old Jan 15th, 2022, 13:52   #1
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Default Rebuild transmission / uprated parts

I've got an 2003 XC90, D5 (d5244t I think) that I've been working through getting it solid.

I've got a core plug oil leak. So I'll be taking the engine out and separating the transmission to sort it.

I haven't had the car long and have only done around 200 miles or so in it, the transmission felt OK but I don't really have much experience driving autos, especially an old one like this.

While it's all out, I'm thinking on whether I should get the transmission reconditioned for peace of mind - from what I know, the auto box is really the weak link of these cars and I don't want to have to get it all back out after I've already done the job once. I have a few questions:
  • Has anyone used anyone to rebuild these that they can recommend? What was the cost?
  • Is there any sort of uprated parts that can be fitted to make them more reliable?
  • Are there any other compatible transmissions that are more reliable?
  • Is it worth trying to do it yourself?
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Old Jan 15th, 2022, 18:15   #2
john langrick
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Hi, you need to check the AWD spline drive, it is almost certain it will have failed if it has not been upgraded.

Check this by laying on your back with feet forwards and arms just forward of rear wheel arch. It helps to have rubber gloves. Grip the propshaft, in the centre of the car transmission tunnel and try and turn it. If it does turn then the spline gear has failed.

If it has failed you need to check theating part in that angle drive. This often fails when the spline gear has stripped.

I would suggest the gearbox itself is a specialist rebuild but your personal skills unknown.

Unless there is a definite issue when driving clunky changes or flaring, then suggest leave well alone

A good and complete flush will be a good idea and suggest the gibbons method ( search on the forum) be a good method but others have their favourite flush method.

I also have a my 03 so have t shirt on most of the above issues.

With engine out check turbo end play and condition of engine mounts.

Good luck and let us know how you get on.

John l
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Old Jan 15th, 2022, 18:25   #3
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If it is driving fine I wouldn’t take the gearbox apart for the sake of it, I had mine rebuilt and it was a 3k bill it was the six speed and it had a new torque converter and valve block and a new spline kit.

But saying that if you have taken it out it would be a lot cheaper. But you can drain all the oil out as you can tip it to empty it out and completely refresh the oil.

Good luck whichever route you choose.

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Old Jan 15th, 2022, 18:33   #4
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Cheers both

Already checked and the 4WD is fine on this one

Ill leave as is for now since its doing it's job
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Old Jan 15th, 2022, 19:54   #5
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2-3k for a gearbox recon (I know a guy who knows a guy but nowhere near Harrowgate unfortunately) and not for the lighthearted to do... I would have the oil checked though, just see what it's like... And if there is some jumpiness or hesitation in the shifts to check all the engine mounts before going down the gearbox rebuild road (and before that is the slush-flush.
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