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Discussion Starter #1 (Edited)
Note that the vin break listed, even in the '99 slide is a '98 vin break. These early ones use SKF bearings. The pinion bearings are the same as RWD 1031 rear pinions: 183841 (HM89449) & 183839 (M86647). Bearing cups are HM89410 & M86610. Main shaft bearings are 32010x, same as AWD Diff.





mid 98-99 style



longer pinion to diff casing offset, recessed yoke for CV joint (unlike early '98) 3 versions shown:



Volvo reman mid 98-99 unit 8602679 (NLA)



'00 ONLY


note the shorter pinion to diff casing offset - which indicates that the right side driveshaft will also be different than '99, having a longer shoulder to provide a seat area for the BG (outer casing) inner seal.





Note 1 : 9183491 shaft = chassis range S70 465739-621367 V70 465339-630091
9463300 shaft = chassis S70 621368 - on V70 630092

The production change here was in regard to the center bearing - later shafts have a larger bearing & carrier.
Note 2 pertains to the fact that the replacement CV ONLY fits original Prop shafts





 

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Discussion Starter #2 (Edited)
Driveshafts - mid 98 - 00



EDIT 3/08/14: Carrier variations - note that the later 99-00 DS with larger (better) carrier bearing CAN BE USED in late '98's - you have to re-drill the carrier mount holes in the support plate to 2.25 on center, inboard of the existing 3" on center holes.



Driveshaft/Exhaust support bracket: 9474483 (98-99) 9133420 ('00, NLA)



listed as position 19 in the Front Floor Section.

Torque Tube/ VC variations





mid '98-'99 BG length



'00 BG length



change in sump design





BG internal components





Difference in '98-99 & '00 Pinion - '00 uses Koyo bearings, smaller OD



SKF pinion bearings: 183839 (M86647) & 183841 (HM89499) - same as used for the RWD 1031/1041 diff pinion. Carrier bearings: 32010x (2)

M6647 (183839)


M69410




Don't have the numbers for the Koyo bearings (EDIT 32006J )



Diff/BG coupler current PN : 31256008 (manual)



check for spline wear here:



Reference thread on V70R regarding Spline Coupler construction analysis

Inside Viscous Coupler



Freewheel Mechanism



Design & Function




Typical torn front CV boot





Binding CV due to lack of grease/cooked - typical cause of vibration



CV components



Re-assembled, ready for CV grease - note markings to ensure correct reassembly

 

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Great post Hussein! This should really be stickied. Thanks for taking the time to document all of that.
 

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Discussion Starter #4 (Edited)
Right Axle Variants '98-00

'98-'00 front to back. Arrow indicates seal seat (28mm OD).

EDIT: Carrier Bearing VO 9181693 (FEBEST 45x75x19)



So, the '00 (R) axle doesn't work in an M66 AWD because it's too short. Fixed point is the bearing, since that is located on the engine in the same location regardless of transmission. This is from a 5 speed Auto AWD (R, # 8251521 (8601580) (9463921). If there were any 4 speed Auto AWD in '00, I would expect that it would work as is. The '99 axle PN 8251520 (8601576) (9463762) will work, but the outer BG seal seat is not in the correct location. '98 auto AWD axle pn: 8251509

EDIT: There seem to be 2 '00 AWD 5 speed auto axles. The one pictured, is from an R. I took an axle from an '00 XC today, and it looks like the earlier design; the PN is 8251523 (8601589) (9463351)



Either a .5mm collar needs to be fabricated for the seal to seat (1mm difference in OD between seal seat & rest of shaft), or a smaller ID (27mm) seal would need to be sourced. Probably easier to look for a seal, IMO

28mm ID


38mm OD



Shaft OD

27mm

 

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Discussion Starter #5 (Edited)
The '00 XC 4 speed auto axle (9463351) 8251523 is the correct axle for anyone doing an '00 M66 conversion

2nd from top, incorrectly described as XC 5 speed auto (top axle is the R-only 5 speed axle)


'98/99 offset compared to '00 (top)


The problem is that the aftermarket sources have the listings all screwed up. If you order a 8251253, it is (incorrectly) superceded to 8251251, which is the Volvo # for the '00 R axle. The correct axle is sold under 8251520, which is the Volvo # for the '99 axle!

 

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Thanks for posting this information, it's come in handy and I've learned a bit from it. I see the section on the lock-up mechanism under the freewheel description is cut off and was wondering if anyone could help me find that information. Would love to know more about how that works.
 

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Discussion Starter #7
Thanks for posting this information, it's come in handy and I've learned a bit from it. I see the section on the lock-up mechanism under the freewheel description is cut off and was wondering if anyone could help me find that information. Would love to know more about how that works.
It's actually shown in the pic - the ramped ball bearings constitute the centrifugal lock-up - they are thrown outwards & lock the inner & outer shafts. When that goes bad, it sounds like a bag of bearings being rattled around in a tin can.
 

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Discussion Starter #8 (Edited)
BG seal part numbers:

Carrier seals (2) 9143879 (position 3 in the '00 diagram, same part for 97-)
Driveshaft seals (2) 9143885 (where shaft passes inside BG, and into differential)

Crown nut O-ring (1) 925258

Fill plug seal (1) 11998

Pinion seal (1) 9183891 (I would NEVER replace this unless it's obviously leaking! Just like the rear diff, there is a compression collar that sets the pinion backlash - if you don not torque to spec, you WILL damage the BG!)



Diff sleeve outer seal (automatic trans AW50-42) (1) 9496129
Diff sleeve outer seal (automatic trans AW50/51 AW55-50) (1) 8636194
Diff sleeve outer seal (M66) (1) 9143911

Chromed Diff/BG Sleeve (1) 31256008 (9181408) (Manual trans)
Oring (1) 976041

 

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Discussion Starter #9 (Edited)
Diff/BG collar: What to look for. Typically the splines will wear on the BG side of the collar. What you need to look for in terms of wear is that the splines still have a 'flat' between each valley:



Look at this pic, you can see the splines are worn to a sharp edge, next step would be stripping of the collar, and subsequent damage to BG

 

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Wow (H/LookforJoe),
detailed, time consuming, and yet extremely valuable.
As a new member, I will speak for the "future members of the community" to say
"Thank You" for generously putting in the time and effort to document your experience and share it with us.

Kudos also to all those that keep this opportunity open to us (via the forums/site).
 

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Discussion Starter #11 (Edited)
Update. IPD now sells an AWD right side axle that will work on both '99 and '00 4spd auto models - which means you can replace your dead '00 BG with the more readily available (late)'98-99 BG's, you just have to buy the custom axle from IPD - it has seal seats in two spots, to accommodate both versions.

EDIT: NOTE - The '00 Down Pipe will require modification also if the earlier Bevel Gear is used - the change in offset of the pinion will negatively impact fitment of the stock '00 DP.

IF you are planning a manual AWD swap on your '00 R, you will need BOTH left and right axles (either '99 or '00 4spd) - the 5spd auto axles DO NOT fit the M66/or M58 trans. You will also need the '98-99 trans mount (9161101) instead of the '00 version.

The left axle lacks this shoulder:

this pic courtesy of BlackT5 on VS



needs to look like this:





which the illustrated seal will seal against

 

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Discussion Starter #17
I don't know if it's the camera angle, but is the '00 driveshaft longer than the '98-99?
Also, if I wanted to use a shaft from a '99 XC in my '00 XC, would it work? I have an upper end VIN as far as the VIN split goes and I don't know the VIN of the '99
Not longer.

'99 shaft would work in '00, might need carrier plate depending on which carrier bearing the '99 shaft has.
 

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Discussion Starter #20
BEJinFbk reminded me with his post that I forgot to add this from a few years back - just in case someone tells you that your old AWD can't handle any power...

50/50 torque split started once I went over 350AWHP, 450 here

 
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