Bevel Gear weeping from Seam?

[Inthegroove]

I have the exact same problem with my 04 XC70. What did you end up doing, did you bring the car to a Volvo dealer or did you do it your self? I was looking at pulling my case apart, what do I need to file down?

My 04 XC70 is leaking from the case halves as well. Has anyone successfully split the case and sealed it themselves? I'm ready to pull the bevel gear but have yet to find good tear down instructions of the bevel gear itself.

[Astro14]

Did you check the resources section?

The TSB is posted along with pictures...

http://www.volvoxc.com/resources/how...%20Leakage.pdf

[Inthegroove]

Did you check the resources section?

The TSB is posted along with pictures...

http://www.volvoxc.com/resources/how...%20Leakage.pdf

Thanks. I'm still trying to find my way around the site. Good info!

[Inthegroove]

FYI

Did the case half re-seal today and everything went quite smooth. No trouble with stuck/rusty bolts, axle shaft came right out. If you've got some basic wrenching skills and a decent set of tools, this job can be done in your home garage with the car on jack stands. Make sure you have a good selection of ratchet extensions and wobble sockets to get those hard to reach bolts on top of the bevel gear and to unbolt the rear drive shaft. This will allow you to unbolt the drive shaft from the bevel gear without dropping the exhaust like the service bulletin suggests.

[JRL]

Did you bevel the inner joints like you're supposed to?

[haoz129]

Going to do the same.

Bought seals, bolts and new vent.

Didn't buy the Chemical Gasket for which dealer asked over $60.
I decided to use a general Gasket Maker purchased from other parts store, $20.
I think it will work.

JRL,

Any comment on beveling the inner joint, must do, why ?

Thanks.

[Inthegroove]

Did you bevel the inner joints like you're supposed to?

I did bevel the inside edges. Although I did not use a file for most of the job as stated in the TSB. Instead I used a de-burring tool which proved to save TONS of time, with the same result. I did have to resort to a file for some of the tighter radius corners and hard to reach areas around the fill plug.