XC90 AWD Diagnosis

[rsymes2k]

Hi Everyone,

First time post but i've been searching on here for some time! Sorry if this is covering old ground but i'm having difficulty finding definitive answers

I've read a lot of threads on the AWD system on the XC90...

I have a 54plate xc90 D5 auto, needless to say I found out at the weekend the AWD isn't working, I took it to Maxwells in Mortonhampstead for a quick once over and he said it's not working and suspected the rear diff had gone.

As per usual i've had no fault codes, plugged in my code reader and nothing is coming up (albeit a basic code reader)

So, I then started trawling the forums etc for information and have come across the following....

Splined sleeve failure - causing drive to be lost to prop shaft out of angle gear, sometimes angle gear has to be replaced in addition.
Question is diagnosis on this, I've read of people being able to spin the prop shaft, if you can then this is usually the splined sleeve which requires replacement, however I've called Maxwells back this morning and they've said this isn't the case? If you can spin the prop shaft then it would point to the rear diff letting go? I guess the next step is pulling the propshaft off and looking at the sleeve but Maxwells said if that's gone then really it makes no difference as the rear diff is just letting the propshaft spin?

I've also read of the DEM failures - caused by the module itself or the pressure sensor but as far as I know this would log a fault code?

If anyone can assist it would be hugely appreciated!

[Ducklakeview]

Originally Posted by rsymes2k

Hi Everyone,

First time post but i've been searching on here for some time! Sorry if this is covering old ground but i'm having difficulty finding definitive answers

I've read a lot of threads on the AWD system on the XC90...

I have a 54plate xc90 D5 auto, needless to say I found out at the weekend the AWD isn't working, I took it to Maxwells in Mortonhampstead for a quick once over and he said it's not working and suspected the rear diff had gone.

As per usual i've had no fault codes, plugged in my code reader and nothing is coming up (albeit a basic code reader)

So, I then started trawling the forums etc for information and have come across the following....

Splined sleeve failure - causing drive to be lost to prop shaft out of angle gear, sometimes angle gear has to be replaced in addition.
Question is diagnosis on this, I've read of people being able to spin the prop shaft, if you can then this is usually the splined sleeve which requires replacement, however I've called Maxwells back this morning and they've said this isn't the case? If you can spin the prop shaft then it would point to the rear diff letting go? I guess the next step is pulling the propshaft off and looking at the sleeve but Maxwells said if that's gone then really it makes no difference as the rear diff is just letting the propshaft spin?

I've also read of the DEM failures - caused by the module itself or the pressure sensor but as far as I know this would log a fault code?

If anyone can assist it would be hugely appreciated!

Ignore the dealer, they are talking bollocks, indeed their lack of knowledge is quite frightening, and I for one would have zero confidence in them working on my car!

The prop should be permanently connected to the final drive/gearbox at the front of the car and AWD is activated via the Haldex clutch on the rear axle when required.

If you can turn the prop with the wheels on the ground, then the problem lies at the gearbox end, and is normally just the splined sleeve. Sometimes, but not too often, it can damage the input shaft to the transfer box, but normally a replacement sleeve solves the problem - Around £100 for the part and £300 labour if you aren't doing it yourself.

Mike

[rsymes2k]

Originally Posted by Ducklakeview

Ignore the dealer, they are talking bollocks, indeed their lack of knowledge is quite frightening, and I for one would have zero confidence in them working on my car!

The prop should be permanently connected to the final drive/gearbox at the front of the car and AWD is activated via the Haldex clutch on the rear axle when required.

If you can turn the prop with the wheels on the ground, then the problem lies at the gearbox end, and is normally just the splined sleeve. Sometimes, but not too often, it can damage the input shaft to the transfer box, but normally a replacement sleeve solves the problem - Around £100 for the part and £300 labour if you aren't doing it yourself.

Mike

Ok great, so worst case scenario it's a new angle drive + spline sleeve (without the angle drive with any luck!

Slightly concerning that this is a local volvo expert garage... He originally said I needed a whole new axle, which then ended up being just a rear diff, which now sounds like it's just the spline sleeve (i've moved from about £4k to repair to hopefully £600!)

I wasn't 100% certain that the haldex was disengaged completely with the vehicle stationary (not sure why as my old allroad disengaged it completely)

I'll probably opt to get the fluids changed in the diff too, is it advisable to just stick with the volvo recommended or something else?

[Ducklakeview]

IIRC, the diff and the Haldex have different, and wholly incompatible fluids. TBH, as long as the rear diff level is ok, I'd not bother changing it, as it doesn't do that much work. Haldex fluid and filter are a worthwhile change, and only get them from Volvo. If the angle gear is coming off, again, it's wise to change the fluid, synthetic single grade gear oil, can't remember the SAE though. Gearbox fluid is specific, only Volvo or Toyota approved, ASIN WARNER Type JWS 3309 cheapest around is Ebay; http://www.ebay.co.uk/itm/2216933469...%3AMEBIDX%3AIT

Mike

[ianu]

Originally Posted by Ducklakeview

Ignore the dealer, they are talking bollocks, indeed their lack of knowledge is quite frightening, and I for one would have zero confidence in them working on my car!

The prop should be permanently connected to the final drive/gearbox at the front of the car and AWD is activated via the Haldex clutch on the rear axle when required.

If you can turn the prop with the wheels on the ground, then the problem lies at the gearbox end, and is normally just the splined sleeve. Sometimes, but not too often, it can damage the input shaft to the transfer box, but normally a replacement sleeve solves the problem - Around £100 for the part and £300 labour if you aren't doing it yourself.

Mike

Plus 1 here. You don't give mileage on your original post, but, yes the sleeve is the week link here. Depending on miles and how long it's been broken, brace yourself for a new angle gear. If the splined shaft is damaged too far, it's pointless putting a new sleeve on it.
The angle gear new, is part ex only with Volvo, and would be over £500 (I can't remember how much I paid for mine) - but you might be lucky though. Mine lasted until my 3rd sleeve before I had to replace it ;-).
A good recommended Indy garage should be able to tackle this no problem - they can still use the genuine parts or part ex'd parts for you.

Cheers
Ian.

[rsymes2k]

I'm at 130k miles! I'm hoping it's not the angle gear too!

I've taken it to my usual indy dealer rather than the supposed volvo specialist now... Booked in for Tuesday so here's hoping!

[swedishandgerman]

Just get the thing up the road to Wellington! Take it to Formula Cars

[rsymes2k]

I would but it's getting up / back from Wellington while they're fixing it!

[swedishandgerman]

Originally Posted by rsymes2k

I would but it's getting up / back from Wellington while they're fixing it!

They lend out fantastic cars, like 850's and old shape V70's!

[DavidSW]

+1 for Formula Cars. They really know their stuff, prices are reasonable, and as long as they know beforehand, a courtesy car won't be a problem. (You won't get a brand new XC90, but you'll get something that starts, drives and stops OK, which is really all that's necessary.)