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So, I pulled out the diff. and looks like I'm sh*t out of luck. The splines coming off the diff. to the angle gear are a part of differential(all one piece).<p>So, would it be possible to repair the splines on the diff. by filling and re-grinding? Or possibly cutting off that section and welding on new splines?<p>...or should I start begging volvo to help me get the part from the plant?<p>Here's some pix:<br>Gearbox<p><IMG SRC="http://i161.photobucket.com/albums/t215/rushin_album/DSC03677.jpg" BORDER="0"><p><IMG SRC="http://i161.photobucket.com/albums/t215/rushin_album/DSC03681.jpg" BORDER="0"><p>Diff. splines<p><IMG SRC="http://i161.photobucket.com/albums/t215/rushin_album/DSC03684.jpg" BORDER="0"><p><IMG SRC="http://i161.photobucket.com/albums/t215/rushin_album/DSC03683.jpg" BORDER="0"><p><br>btw, anyone know the part# for that green o-ring?
 

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****it FWD <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/biggrin.gif" BORDER="0">
 

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FV-QR

god save me now. this is not the first i've heard of this failure.
 

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Re: FV-QR (Evos_R)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>Evos_R</b> »</i></TD></TR><TR><TD CLASS="quote">god save me now. this is not the first i've heard of this failure.</TD></TR></TABLE><p>This<I> is</I> the first time I've seen the transmission/differential side splines this bad. I thought that shaft was harder and that's why most times the splines last much better than the splines on the angle gear side. But that thing is bad. <p>
 

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Smooth it out and weld on the spline shaft and leave the side into the correct. <p>Before doing this I would make a custom one out of ...... before doing this <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/biggrin.gif" BORDER="0">
 

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Re: (Chilled Man)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>Chilled Man</b> »</i></TD></TR><TR><TD CLASS="quote">Smooth it out and weld on the spline shaft and leave the side into the correct. <br></TD></TR></TABLE><p>Based on no knowledge at all, this seems like a decent plan<p>OP: as always, thank you for being a pioneer and showing us the gory details
 
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