XC90 T6 transmission failure

[sandog]

I have a 2005 XC90 T6 (124,000 miles) with a potential transmission problem which could fail anytime. I've read some fail at 30,000 more or less and some on their 2nd, 3rd or 4th transmission. Have done flush and don't ride it hard. Used on weekends and for long trips. I know that having Volvo pay for this widely known problem will probably not even happen even with an act of congress.

So, my questions are...has anyone had theirs replaced with a hd rebuilt from a performance shop? I know these are GM transmissions and I have found several sites that sell beefed up hd transmissions for around $1500 give or take. I was thinking to better invest in a known good transmission rather that fight with Volvo and end up with the same type transmission. Any thoughts, any recommendations (shop, prices, vendors, etc.???) I love my XC90 and I think if not for the transmission problem I could get good use out this for much longer.

I have a 2001 Chrysler Sebring Coupe with 345,000 and 1991 Nissan Maxima with 425,000 miles with no major problems (both hard driven)...just the routine maintenance keeps these two running. My Volvo??? OMG! I feel cheated...

Thanks

[markwemple]

I want to commend you, or assure you you've had amazing luck getting a Chrysler and a Nissan past 100k w/o problems. I have zero faith in those 2 marks.

Best of luck on the tranny issue. I have't heard of an "improved" version. Waht exactly is happening that leads you to believe that failure is immenent.

[dmd]

It is just a GM tranny in a slightly different configuration. I have spoken to a few
shops for a buddy and they say it is the same one, but they have no cores to build
you one from. They will have to pull your tranny, build it, put it back. Expect it to
take a bit longer because they have not worked on that specific car before. Make
sure to get a very reputable place, very clean, almost surgical clean shop. If it is
a messy place then they will do a dirty job and transmission rebuilds MUST be
extremely clean.

A good performance shop for these trannys should be able to beef it up pretty
well.

[mgjonesin]

We got Volvo to replace it even though it was out of warranty.
This should be a recall.

Our problems started right after the left axle shaft failed.

I think the real problem with them is that a failed axle will allow axle grease to mix with trans fluid. Needless to say that doesn't do the trans any good.

Anyway, when they replaced my trans they also replaced the other axle and the trans cooler to prevent contamination of the new trans.

As a note, it seemes the new axles had been redesigned. Maybe to prevent these problems in the future.

Good luck,

Jon

[sandog]

If you hear a loud bang like you ran over something or like you kicked up a rock, well congratulations, the pin on driver side axle shaft has snapped, and at that point you are currently contaminating your transmission. In about 400-700 miles you will start to experience the joy of transmission slippage. To verify this event, just look at the trans fluid. Good trans fluid looks like cranberry juice. Contaminated fluid will look like greyish black and it will stink!! What is happening inside the transfer case, which contains a separate fluid type (Totally Different Fluid); it's now being pumped into the transmission fluid. The poorly designed GM transmission doesn't like this. Fluid is being allowed in by the missing/broken axle shaft pin. (Taken from another post)

This past weekend I have experienced a bang (not so loud)or like I kicked up some gravel in my wheel well. My transmission fluid still looks good and shifting is good as well. If there is merit into the above post, how would I fix the pin that snapped. What is that pin? Reading all the posts it only mentions the clip. In VADIS does not show a pin. Can anyone explain this? Ever since this happened I hear a low toned grinding or rubbing noise, something like a worn brake pad (I checked my pads and they are still thick). When I accelerate it goes away, when I let off the gas I can hear it and when I coast. When I step on the brakes it goes away. I only hear it at about 25MPH and above. My axle boots are all intact. I plan to jack up the vehicle and listen to it where I don't have wind or road noise or listen to it without the axles...I'm stumped!

(I thought that the incident was due to the transmission failing as I said in my previous post. But I found a post somewhere that was identical to what happened last weekend.)

[Forkster]

sandog - if what I'm reading is correct, are ALL T6 transmission failures due to the pin on the drivers side axle snapping and as a results contaminates the tranny fluid?

Of course, any transmission which experiences a alien fluid WILL cause it to malfunction. Just curious if 99% of the T6 transmission issues are related to this?

[sandog]

I don't know? This is really strange because I've probably gotten a hold of every diagram there is and could not find what "pin" they are talking about...

[mgjonesin]

When I replaced the drivers side axle I removed the screw for the drive shaft, and trans fluid began to pour out of the hole.

Now I don't know allot but I was pretty sure it wasn't supose to do that!

Once I removed the axle I looked inside the inner CV spline, and there was a piece broken out (about quarter size). This allowed the trans fluid to mix with the axle grease.

It wasn't long before the trans started slipping.

[sandog]

How did you convince Volvo to replace your transmission? I read a lot of stories and they vary. It seem that Volvo is selective on who they take care of. Is there any criteria to meet?

On a different subject, was there any fix to what you discovered about the broken piece in the inner CV spline? I could not find any diagram that shows anything inside the spline.


Thanks

[mgjonesin]

We wrote a email to Volvo corporate pointing out the inadequacies of their T6 transmissions. Pointing to numerous blogs and other resources that we found. Also, that Volvo is suppose to stand for quality. I think we mentioned that Volvo SHOULD be recalling these transmissions on their own. In the end Volvo did the right thing for us. My wife wrote the email and was very diplomatic about it. No anger just facts and calling on there corporate responsibility to provide the product they promoted.

The piece that was broken inside the CV was the thin metal wall that separates the inside of the CV spline (transmission side) from the inside of the CV joint (grease side). Thus allowing the fluids to mix. I think this is a DESIGN failure. Its not a separate piece that broke, it was more like something punched a piece out. It was stamped out like a slug from a metal electrical outlet box in a new construction home. Somehow the splined shaft from the transmission was driven to deep into the CV.

We were given the go ahead from corporate to take it to a dealer. The dealer asked allot of questions like were we the original owners and where we bought it etc. I don't know if any of that mattered by that point or not.

[sandog]

Thanks for the info. I put the XC90 on stands and ran it. The grinding sound is definetely coming from the driver side axle. I really can't tell if it's the bearings or the transmission and I don't see any leakage whatsoever. I won't be able to isolate the noise without removing the axle. So, my next move is to remove the axle and determine what has been damaged...axle bearings, transmission or something else. Hopefully, I won't have to deal with Volvo USA.

Thanks again. I'll keep you all posted!

[JRL]

How did you convince Volvo to replace your transmission? I read a lot of stories and they vary. It seem that Volvo is selective on who they take care of. Is there any criteria to meet?

On a different subject, was there any fix to what you discovered about the broken piece in the inner CV spline? I could not find any diagram that shows anything inside the spline.


Thanks

Very easily
The 04 T6 I just sold had a new tranny installed by Volvo mostly for FREE.
New tranny, new radiator, new coolant line
All parts paid by Volvo, labor by me so for about $1100 I had all those parts installed!.
All you need to do is (forcefully [sly] ) ask/beg them for one

[sandog]

I finally got the axle off. When I removed the bolt on end of the drive shaft fluid poured out. Yes, just like mgjonesin there is a broke off piece of metal as big as a qtr. inside the tx side spline area. I tried to spin the transmission but fluid poured out of the transmission at idle. So, there is no way for me to tell if I could still hear the grinding noise. So, here's my plan...get a new axle, install it and hopefully not hear the grinding sound. I guess the reason why the axle (maybe) could be grinding because the grease inside has been washed away by the tx fluid?

Any suggestions?

[JRL]

[thumbup]


Any suggestions?


Yes I do, stop working on this yourself.

Volvo is paying for new transmissions, radiators and coolant lines.
(You may have to pay for labor but spending $1000-$1500 is far better than $5000++!)
All you need to do is push them a bit. Volvo has admitted that this was an under/poorly engineered car and is making good on most of these.
They're even paying for second transmissions at over 100K if the car otherwise is well maintained! [thumbup]

[sandog]

JRL, Thanks for the advice! but it may be easy on my part to convince Volvo!

Any tricks or methods to convince Volvo? Did you write or call them? If you don't mind what/how did you say or ask? Did you take the car to the dealer and left it? Mine is at home right now. Yes, this car is pretty well maintained @ 124K miles. I only drive it on the weekends. I'd like to keep it!

Thanks again!

[JRL]

Go see your service manager.
You tell him you know of SEVERAL 04T6 XC90s (some with high miles) that have had new transmissions fully or partially paid for by Volvo and you KNOW that Volvo is doing this.

You get him to call Volvo warranty and get an authorization
(and have him get off his ass and do his job for the customer).

It helps that I have a very good relationship with my dealer, nevertheless, many are being replaced (for free), even the high mile ones.

You need ALL the pieces, radiator, tranny and tranny oil line, related
O-rings and gaskets.

I didn't have to do anything, I asked for my price for a tranny install.
I came back later in the day and he said
"just pay me labor" I got you a transmission (and the other stuff)

[SurfDog]

This description from one of your posts was EXACTLY what I experienced today: "Ever since this happened I hear a low toned grinding or rubbing noise, something like a worn brake pad (I checked my pads and they are still thick). When I accelerate it goes away, when I let off the gas I can hear it and when I coast. When I step on the brakes it goes away. I only hear it at about 25MPH and above. My axle boots are all intact.". This guy was reading my mind.

I was hoping for brake pads, and would have been *happy* to just replace a CV joint.....but the fluid on the tranny stick is bubbly, stinky and grey. I've got the tx problem. Glad I found this thread from you guys. Saved me time and (hopefully) money.

PS: My 2005 XC90 T6 has a 100,000 mile extended warranty. Anyone want to guess my milage today? (100,058).

[JRL]

But your heard these noises more than 58 miles ago, yet you waited..... [sly]:confused:

[SurfDog]

....and she said she didn't hear anything. "Gee, maybe that's because you're always blasting the radio." The Service Manager at my dealer is going to push for a new one. He knows the issue well, I'm hoping it will work out.
Thanks again. Great Forum.

[sandog]

I am saddened to announce that VOLVO has refusedto compensate me at any cost even though this problem was well known. So my next move would join a class action lawsuit and send a letter to Sweden. Does anybody think that is a good idea? Hey, maybe those higher ups are not aware? I highly doubt it though?
The reason why they did not want to cover it was because I had 124K miles on it. So, I asked VOLVO...what would be the difference of a 50K hard driven vehicle to a 124K lightly driven vehicle? My answer was, the 50K would fail before the 124K one.
So, for you guys out there...drive that vehicle like there's no tomorrow for 100K miles and it's sure that VOLVO will replace that transmission. This came from VOLVO NA Customer Care...they will only replace transmissions with 100K or less, NO QUESTIONS!
If anybody out there knows of a good tx rebuild shop let me know...

[padremiguel]

I recently purchased a 2004 XC90 T6 AWD with 82k miles on it. I took it to the dealer to catch up on any "deferred" maintenance.

One suspension component replacement required the front axles to be removed. Once removed, they called and said a plug had cracked in the axle allowing grease into the transmission. They also assured me that there had been very little leakage at that point and that a new axle and a transmission flush would put everything right.

I've been edgy because of an occasional hard jolt when accelerating from a stand still. The dealer found the transmission was a bit low on fluid. They also made other adjustments and so far so good. That work and a window regulator rivet replacement (wicked door rattle) cost $5.18. Highlight of my day.

After reading this thread I feel like I've dodged a bullet with the transmission failure. At least I hope I have.

[JRL]

You haven't, they almost ALL fail at some point.
Hopefully you will beat the odds

[JRL]

This came from VOLVO NA Customer Care...they will only replace transmissions with 100K or less, NO QUESTIONS!
If anybody out there knows of a good tx rebuild shop let me know...

NEVER talk to those a-holes.
You need your service manager to PUSH for parts... he knows who to call.
Mine had 118K, was on its SECOND (2nd) tranny and it too was replaced.
All parts were paid for, as I said, I paid only labor.
Tranny, radiator, coolant line, fluid
You need to make a deal

You want to start a class action?
I would give this a 90%+ chance of winning
Please include 2001 and 2002 5 speed GT trannies in the lawsuit
and while you're at it, including common failurers, 1996-2001 ABS modules and AC evaporators from 1994 thru 2000 on ALL S and V70 models.
These are close to 100% premature failures on all these parts