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Discussion Starter · #1 · (Edited)
Hello everyone. I am planning to change the angle gear sleeve by myself on my 2004 S60R so I need some guidance. I looked through alot of threads but found only a few pictures of the process. If anyone has some pictures with a step by step guidance and some close up pictures of the good and bad splines on the input shaft and the sleeve, it would be perfect. Also if someone has one of those diagrams that shows what is inside the angle gear and how it all comes together and how it is attached to the tranny it would be good to see it too. I remember there was a nice video on youtube, about a year ago, which did a really good job explaining everything for DIYers. I think the video was broken up in two or three 10 minute parts. I tried to find it but couldn't. Does anyone know how to find that video?

Also where is the best place to get the sleeve and does it come with all of the seals? I heard it is also a good idea to replace the transmission seal while doing that? And I think so far I need the gear pull tool, and the tool to install the seals. Is it correct? If I need anything else please let me know.

Thanks everyone :)
 

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ya the guy who made those awesome videos up and left Chicago area and no one knows what happened, his videos are gone too as is his shop.

Best place for the sleeve is Tasca... start searching clutch repair and slave cylinder repair threads for the tasca parts list that is where I got my list when I did mine. I cant remember which thread it was in though
 

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you will need everything that is required for doing a clutch... which means dropping your subframe... hope you have a lift available!
 

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you will need everything that is required for doing a clutch... which means dropping your subframe... hope you have a lift available!
No, you don't need to drop the subframe.
 

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FV-QR

Oh, and in that thread the guy removed the downpipe... This is not needed. You can get to the bolts for the drive shaft (going to the rear of the car) with a air ratchet and socket, or a t-handle hex tool.
 

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2 9143885 Drive shaft seal O.DIA 38 mm $16.62
3 30735126 Sealing ring O.DIA 65 mm (9143879) $23.23 x 2
4 977023 O-ring $4.13
5 11998 Gasket $0.91
6 30713275 Plug (3549308) $1.68
7 30684243 Sealing FOR 8603809 FOR 36000272 FOR 36000340 45x65x10 $11.66
7 9183891 Sealing FOR 8602919 39.4x65x10 $11.66
8 30735301 Companion flange FOR 8603809 FOR 36000272 FOR 36000340 $128.14
8 8675090 Companion flange FOR 8602919 FOR 8603809 $128.14
9 3549685 Flange lock nut M24x1.5x18 $8.60
10 1377065 Lock washer FOR 8602919 FOR 8603809 $1.37
10 30783267 Lock washer FOR 36000272 FOR 36000340 $1.64
11 985174 Flange screw FOR 8603809 FOR 36000272 M8x20 $0.99
11 988182 Flange screw M10x20 FOR 8602919 (946441) (982815) $1.22
12 987985 Flange screw M10x40 FOR 31256246 $1.20
13 9143878 Adjusting nut $38.73
15 986701 Screw with pin M8x30x58.5 $6.68
16 30681138 Filter $4.51
17 8689527 Bleeder nipple $2.82
18 31256246 Service kit $169.36
19 31256008 Sleeve (9181408) $102.00
19 9495034 Sleeve $102.00
20 8636196 Snap ring $14.12
20 977101 Snap ring $1.03
21 30651512 Oscillation damper DSL V70 FC1; CH -427634. V70 FC2; CH -427179. S60 CH -397216. XC70 CH -158967 $99.98
21 30713096 Oscillation damper DSL V70 FC 1; CH 427635-, FC 2; CH 427180-, S60 CH 397217- XC70 CH 158968- $104.24
22 985868 Flange lock nut DSL, 8x8.8 V70 FC1; CH -427634. V70 FC2; CH -427179. S60 CH -397216. XC70 CH -158967 $1.44
22 982763 Flange screw DSL V70 FC 1; CH 427635-, FC 2; CH 427180-, S60 CH 397217- XC70 CH 158968- M6x45 $2.40
23 1161748 Grease, splines joint FOR 31256246 $6.65
24 8636195 Drive shaft seal O.DIA 43 mm $14.12
24 9143885 Drive shaft seal O.DIA 38 mm $16.62
25 9143911 Sealing ring O.DIA 75 mm $14.12
25 8636194 Sealing ring O.DIA 75 mm $14.12
26 976041 O-ring FOR 31256246 $2.92
27 987985 Flange screw
 

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warranty

Would something like this be covered under warranty? I purchased a warranty with my 2004 S60R with 54000 miles on it. Car has all service documented. When does angle gear usually become a problem?

Starting to have issues with parking brake in the morning - need to give it some gas in the morning...then her a pop sound and get rolling.

Warranty I got was a 3 year 36000 (all electrical/mechanical) covered...minus normal wear and tear.
 

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I have heard of them getting resealed or replaced under warranty
 

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Discussion Starter · #11 ·
Thanks everyone this is some great info. It will help me alot for sure. If there are more suggestions and advices keep'em comming. Oh and another question there are two sleeves the older and the newer one. Will both work fine on my 04s60r or should I stick with the older one? Which part number 31256008 Sleeve (9181408) $102.00, or 9495034 Sleeve $102.00?

Thanks guys
 

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Would something like this be covered under warranty? I purchased a warranty with my 2004 S60R with 54000 miles on it. Car has all service documented. When does angle gear usually become a problem?

Starting to have issues with parking brake in the morning - need to give it some gas in the morning...then her a pop sound and get rolling.

Warranty I got was a 3 year 36000 (all electrical/mechanical) covered...minus normal wear and tear.
Mine was resealed under the CPO warranty that the previous owner had on the car.

The parking brake issue is very different but just as problematic. Do a search but please look into this asap. Another SS member just paid two grand to repair the damage caused by delaminated parking brake shoes.

I should add that the parking brake problem would most likely not be covered under a warranty.
 

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i did my sleeve a few months ago.

things to look out for...

when pulling out the axle. dont pull from the end. pull from the center bearing back after you have it out of the wheel hub.

when you are hating life cause you cannot get the top two bolts off the angle gear. go at it from under the car with the downpipe removed. use a 12" extension with a knuckle and a 14mm socket and go over the top of the angle gear to get at those two bolts! took me hours to get that.

once angle gear is off of the sleeve i drilled one hole in the bottom of the sleeve. (make sure no shavings go into the transmission side of sleeve) i stuck a nail puller bar in the hole. put a block between the nailpuller and the transmission and pryed it off. (total pain in the ass) because i only had the one hole to pry from i used a rubber mallet to beat the sleeve square to the transmission to get it off.

when you have the sleeve ready to come off. have a drain pan ready to catch some transmission fluid.

when re assembling. have someone help you line up the drive shaft to the angle gear while you slide the angle gear back on to the sleeve.

i was also told to lube the sh!t out of the sleeve. lack of lube is the major cause of the failures.

if you have any problems pm me and i will shoot you my number if you need it!
 

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when you are hating life cause you cannot get the top two bolts off the angle gear. go at it from under the car with the downpipe removed. use a 12" extension with a knuckle and a 14mm socket and go over the top of the angle gear to get at those two bolts! took me hours to get that.
Or to keep the downpipe still installed... use a 14mm S wrench and apply torque downwards with a pry bar. It is hard to explain, but get an S wrench like this

and once its on the bolt you will see how you can push off the car and the angle gear with a pry bar and have it come loose... Worked perfect to loosen and retighten it. Trust me try it, it takes 3 minutes.
 

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Discussion Starter · #17 · (Edited)
Thanks everyone for all of the advices and help. Really appreciate everyone's input. Now I have to get the parts and get started when I get some free time. And about the two different sleeves...can I use both of them on my 04 s60r or just the older one? Hopefully someone will post a picture of an input shaft? Im just not sure how a bad one will look like. Will it have smooth wear or will it look like pieces of the splines are chipped or something like that?

Oh one more thing which sealant should I use to seal the gap between tranny and the AG?
 

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Discussion Starter · #19 ·
i did my sleeve a few months ago.

things to look out for...

when pulling out the axle. dont pull from the end. pull from the center bearing back after you have it out of the wheel hub.

when you are hating life cause you cannot get the top two bolts off the angle gear. go at it from under the car with the downpipe removed. use a 12" extension with a knuckle and a 14mm socket and go over the top of the angle gear to get at those two bolts! took me hours to get that.

once angle gear is off of the sleeve i drilled one hole in the bottom of the sleeve. (make sure no shavings go into the transmission side of sleeve) i stuck a nail puller bar in the hole. put a block between the nailpuller and the transmission and pryed it off. (total pain in the ass) because i only had the one hole to pry from i used a rubber mallet to beat the sleeve square to the transmission to get it off.

when you have the sleeve ready to come off. have a drain pan ready to catch some transmission fluid.

when re assembling. have someone help you line up the drive shaft to the angle gear while you slide the angle gear back on to the sleeve.

i was also told to lube the sh!t out of the sleeve. lack of lube is the major cause of the failures.

if you have any problems pm me and i will shoot you my number if you need it!
If I run into any problems I'll let you know. Thanks Chris
 

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Or to keep the downpipe still installed... use a 14mm S wrench and apply torque downwards with a pry bar. It is hard to explain, but get an S wrench like this

and once its on the bolt you will see how you can push off the car and the angle gear with a pry bar and have it come loose... Worked perfect to loosen and retighten it. Trust me try it, it takes 3 minutes.
i never even knew something like this existed. i am still assuming you can only get less than a quarter turn at a time tho. that and the fact i have fat fingers would kill me and my impatience!
 
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