AWD driveline noises and leaks

[howardc64]

Back when I had a old BMW 535i, read in a bimmer forum that said consider yourself lucky if your wife doesn't divorce you between 80-120k miles from the maintenance cost. My 01 V70XC is now at 117k! Almost there :)

Dealt with most of the engine+tranny+suspension issues by now. Now on the the XC specific issues... the AWD system. Have the following problems

- A loud ping sound comes from somewhere below the center console. Research shows it is likely the front CV joint on the propeller shaft that often fails on this car due to proximity to a high heat source (cat). Saw circular grease spray patterns on the prop shaft front CV a couple of months ago.

https://live.staticflickr.com/65535/50220182052_90dcf4fb97.jpg (https://flic.kr/p/2jvMytN)DSCF5790 (https://flic.kr/p/2jvMytN)

- A couple of random clicking noises when backing up and putting it in drive. Seems to only happen when cold. Also saw a circular grease spray pattern around the u-joint just before the center bearing on the prop shaft a couple of months ago

https://live.staticflickr.com/65535/50219960321_0ccb17e4cd.jpg (https://flic.kr/p/2jvLqyR)DSCF5787-edited (https://flic.kr/p/2jvLqyR)

Took out the prop shaft last night. Both noises seems to be gone in a quick test drive. Both CV joints and U joint shows no sign of play. Both CV feels nice and tight.

Next I notice wet oil residue on the Viscous Coupler so looks like the Final Drive's ( rear differential) pinion seal is leaking.

So onto my big list of questions :)

- I have to say the car drives rather nice with the prop shaft out. Definitely more power like the T5 I sold and the 02 2.4T FWD I test drove recently. Don't ski and snow hits the ground a couple days a year where I live and I hear about the 1-2 mpg increases without the AWD system. Thinking of leaving the prop shaft out until the winter anyways. My question is

How does one protect the angle gear and VC's prop shaft mounting face from becoming rusty as it is exposed with the prop shaft out? Does it matter if it gets rusted? I'd imagine the face and the bolt hole threads will be rusted from exposure.

- I've indexed the shaft and marked all the hex bolts for balance during reassembly. Research shows new bolts should be used. I presume marking the bolts won't have any value then?

- Prop shaft's front CV service kit is like $250-$300. Given my u-joint also leak and might be the clicking sound source. Seems wiser to get a rebuild from coloradodriveshaft.com? (I think around $500+ with core return, have to call)

- Regarding pulling the Final Drive's Pinion seal, Volvo directions show this tool

https://live.staticflickr.com/65535/50220412531_21507d00e5.jpg (https://flic.kr/p/2jvNJZz)069 (https://flic.kr/p/2jvNJZz)

Would most standard reverseable gear puller work? Or do I need to search for longer and skinnier ones for clearance? Volvo's tool is $300+ from online source.

BTW, pulling the prop shaft wasn't too bad. Had car on 4 jacks, car in D (to rotate the shaft to access the hex bolts) with wife working the hand+foot brake (to hold the shaft firm for removing the hex bolts) while pulling the 12 hex bolts. Hardest part was clearing the shaft from AG+VC. Had to loosen the center bear's mounting plate and the metal shield behind it to get the center bearing bracket to drop enough to clear the prop shaft from AG+VC.

I know, lots of questions, but almost at 120k miles and not too far from my silver anniversary :D :eek: ;) pick the smily of your choice :p

[Aviator]

You gotta remember, the driveshaft is hollow so any tiny bit of movement in the front joint will turn the shaft into an echo chamber/amplifier. Mine's been doing that every now and then (mainly on slopes) for about 5 years and hasn't gotten any worse.

Dave.

[howardc64]

You gotta remember, the driveshaft is hollow so any tiny bit of movement in the front joint will turn the shaft into an echo chamber/amplifier. Mine's been doing that every now and then (mainly on slopes) for about 5 years and hasn't gotten any worse.

Dave.

Yes, I figured that loud metal on metal pinging sound must be from the amplification from the hallow drive shaft rather than other parts of the drive train.

It does seem related to some transmission wear on my car (01), when driving over a typical spot that pings, I brake to turn into a long drive way, gas it a little after the turn and soon letting up the gas to prepare for braking into a left turn into a parking garage. The tranny seems to be shifting up (may not have completed the shift) follow by a immediate release to neutral (from observing the RPM dropping quickly with foot off the gas). There is no bang but barely noticeable watching for it carefully and looking at the tach. With the driveshaft in, I get a ping. With the driveshaft out, all quiet other than carefully observing what the tranny is doing.

The driveshaft's CVs, U-joint and center bearings all looks good and feels tight without any play. The CVs themselves feels much tighter than the drive axles. But of course, my arms aren't going to torque these joints like an engine would :)