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Discussion Starter #1 (Edited)
So our XC90 (05 2.5T AWD) just hit 200K miles last week and I'll have to say it has been very reliable vehicle for us. Then last week as my wife was pulling into the garage this happened...

Anyone here ever seen this or happened to you? What did you guys do to pull it out? I was thinking taking the other side out and hope to be able to punch it out. But I am concerned it won't be that easy and something would be in the way. Or just tap drill, screw and pull with a slide hammer or some sort.

Any feedback would be much appreciated. Thanks
 

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I worked in a tranny shop for many years and have seen this before but not ever on a Volvo.I removed the broken off section by removing the other axle and using a thin steel driver to punch out the broken section.It's worth it to at least take a look at it.The question is why did it break off.
 

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Discussion Starter #4
I worked in a tranny shop for many years and have seen this before but not ever on a Volvo.I removed the broken off section by removing the other axle and using a thin steel driver to punch out the broken section.It's worth it to at least take a look at it.The question is why did it break off.
Ok so on our XC90's there is a chance I'll be able to punch it out from the other side? Need to find a thin steel driver now. Thanks
 

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Make sure you READ this thread below.

2004 XC90 2.5T AWD Broken CV Axle

http://www.matthewsvolvosite.com/forums/viewtopic.php?t=72052


PS: I also have a 1998 S70, recently replaced the seal with Corteco, which is OEM.
Your axle seems to break flushed with the seal, so I wonder if you remove the seal (of course you need to buy a new seal, rmeuropean dot com etc. has Corteco for your car, make sure during install, just drive it in exactly like what you have right now, which is barely 0.5mm below the surface), then grab the broken end of the axle using Channel Lock Pliers or Vise-Grips and pull it out. Here is the info on Corteco seal on the 1998 S70:

https://www.matthewsvolvosite.com/forums/viewtopic.php?t=64252&start=30
 

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Discussion Starter #6 (Edited)
So I got the passenger axle out... And on the left is what I saw (a clear view of what I thought the broken axle on the driver side) and on the right after trying to punch it out.. Bam... A light tap and something started to leak... What did I mess up? A seal, a gasket, or the wall of the transfer case? It sure don't look like the other broken piece I was originally trying to punch out.
 

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Whenever you remove an axle from any transmission, there is always some ATF leaking out. It is normal.

BTW, your seal looks old, personally I'd replace it with new Corteco seals (rmeuropean dot com has Corteco).
 

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Discussion Starter #8
Sounds good thanks... Will invest in new seals. I still have an issue of the broken section of the axle stuck inside on the driver side. Might have to do a drill, tap and pull with a slide hammer process.
 

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I am curious: can you use a long rod and tap the broken end (driver' side) from the passenger side, now that the right axle has been removed?
 

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Discussion Starter #10
I am curious: can you use a long rod and tap the broken end (driver' side) from the passenger side, now that the right axle has been removed?
Well, that's exactly what I thought... On the last picture showing the inner passenger side. I thought I had a clear punch out but something else I punctured. I started to see some fluid leaking inside so I stopped tapping. Part of me says keep tapping but i'm afraid I might do more damage (or damaged already done).
 

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is your passenger side hollow? I've read that earlier XC90's had hollow axles with a freeze plug on the end. If that is the freeze plug, it should have come out with the axle, but some have failed allowing fluid to come through the shaft to the CV. If that is the case, then the plug just was forced backwards, but if it's a metal piece.. the reality is now there is pieces of metal floating around in there unfortunately.
 

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**Sorry, completely missed the fact that something got pushed through when trying to remove the driver side axle and you stopped. Squish and fluid could be a couple of things, and the freeze cap thing is something I never heard of but sure it's legit.**

Were it me, I might pull the angle gear and rework it via that path depending on time and money. I wonder if the fluid is maybe just breaking through sleeve spline gunk (rust, moisture, metal dust ‘cause the spline grease has been long gone)? Can also be trans fluid seepage as the trans side to angle gear sleeve has both an inner and outer seal and at 200k that's a lot of rotations. I’m getting thrown by the depth of the photo but the angle gear is as much as a foot wide before it mates with the transmission, <script id="gpt-impl-0.3865467572282938" src="https://securepubads.g.doubleclick.net/gpt/pubads_impl_107.js"></script>so it’s hard to tell exact<script id="gpt-impl-0.393768357529626" src="https://securepubads.g.doubleclick.net/gpt/pubads_impl_107.js"></script>ly where the “leakage” is noted. Might be interesting to measure and see how far you got to distinguish between angle gear and trans.

Might be a smart investment to take the angle gear off, work the axle through that interface, change sleeve (use all of the tube of grease that'll come in the kit) with seals plus new fluid in the angle gear and feel like you're good for another 10 years.

In the meantime, however you get the axle out, would not hurt to try and run some weed-whacker line (or something flexible that won’t scratch or ding or break off and leave pieces) through the path and get it a little cleaner.

Will be interesting to hear more about this issue over time, especially once you’ve put a new axle back. I too have never heard of a driver side snapping like that and while I don’t work on Volvos for a living, I read a lot about them.

Good luck!
 

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Discussion Starter #13
**Sorry, completely missed the fact that something got pushed through when trying to remove the driver side axle and you stopped. Squish and fluid could be a couple of things, and the freeze cap thing is something I never heard of but sure it's legit.**

Were it me, I might pull the angle gear and rework it via that path depending on time and money. I wonder if the fluid is maybe just breaking through sleeve spline gunk (rust, moisture, metal dust ‘cause the spline grease has been long gone)? Can also be trans fluid seepage as the trans side to angle gear sleeve has both an inner and outer seal and at 200k that's a lot of rotations. I’m getting thrown by the depth of the photo but the angle gear is as much as a foot wide before it mates with the transmission, <script id="gpt-impl-0.3865467572282938" src="https://securepubads.g.doubleclick.net/gpt/pubads_impl_107.js"></script>so it’s hard to tell exact<script id="gpt-impl-0.393768357529626" src="https://securepubads.g.doubleclick.net/gpt/pubads_impl_107.js"></script>ly where the “leakage” is noted. Might be interesting to measure and see how far you got to distinguish between angle gear and trans.

Might be a smart investment to take the angle gear off, work the axle through that interface, change sleeve (use all of the tube of grease that'll come in the kit) with seals plus new fluid in the angle gear and feel like you're good for another 10 years.

In the meantime, however you get the axle out, would not hurt to try and run some weed-whacker line (or something flexible that won’t scratch or ding or break off and leave pieces) through the path and get it a little cleaner.

Will be interesting to hear more about this issue over time, especially once you’ve put a new axle back. I too have never heard of a driver side snapping like that and while I don’t work on Volvos for a living, I read a lot about them.

Good luck!
Been taking naps and dreaming about how I'm going to get it out lol... Looks like i'll be taking out the angle gear next. I'll update soon.
 

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So I got the passenger axle out... And on the left is what I saw (a clear view of what I thought the broken axle on the driver side) and on the right after trying to punch it out.. Bam... A light tap and something started to leak... What did I mess up? A seal, a gasket, or the wall of the transfer case? It sure don't look like the other broken piece I was originally trying to punch out.

That is the seal that keeps the transmission fluid from entering the angle gear and angle gear fluid from entering trans given a failure of either seal. I've seen that seal fail and it can ruin both.
There is NO passage to allow you to "punch" the broken axle out.
You can save yourself some time and money and get a used transmission.
 

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Discussion Starter #16
That is the seal that keeps the transmission fluid from entering the angle gear and angle gear fluid from entering trans given a failure of either seal. I've seen that seal fail and it can ruin both.
There is NO passage to allow you to "punch" the broken axle out.
You can save yourself some time and money and get a used transmission.
I was afraid of that. So even taking the angle gear out will not help me at this point?
 

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Have tried and tried to find some visuals of the axle hole between driver and passenger sides of the transmission to get a better point of reference but there's nothing like someone who has first hand experience with this.

Bummer, was hoping you could pop off the angle gear, release the driver's side axle, do all new seals, sleeve, and fluids and call it a good day. At least you got more reliable info now, I would have felt bad to have provided bogus info.

Good luck!
 

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It will help in that you need to remove it for transmission removal but otherwise no, it will not create a secret passage.
 

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I did find a visual to go along with this: http://volvospeed.com/vs_forum/topic/151069-transmission-specialistrepair/

Plus this for a basic idea as to parts layout (AF33 is the more generic version of the Volvo AW5x) and function: http://shop.ukrtrans.biz/wp-content/uploads/catalogs/AF335.pdf

And this YouTube video, various times you can see the differential (beginning 18:45 or so)- https://www.youtube.com/watch?v=5h-8tpF-zPk, with a good shot of the passenger side beginning 25:40 showing the press in cap plus the interior bar of the differential clearly visible later.

Makes perfect sense now.
 

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- I am not sure you need a new transmission. You may have knocked off the delicate sealing relationship between the sleeve and the angle gear seal. Nothing to worry about.

- Search different forums for the "cutaway" view of the Trans and Angle Gear relationship (think like an engineer). Basically, once the Angle Gear is out, you will see something like this (photo taken from my other DIY):




- You can only assess the situation once you have the Angle Gear out and post some photos here.


PS: Even with damaged sleeve, you can still drive the car, it is just FWD instead of AWD.
 
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