Thanks for the link! It was rather impressive to see how the guy was able to piece everything together, and the picture of the pinion gear helps make sense of things.
Unfortunately, as I tore down the compression flange it was apparent that the problem is within the angle gear casing itself. I was able to push and spin the pinion gear within the case and feel it wobble and smack against the ring gear. From the pictures I saw, the free play on the pinion gear most likely results from one or more of the bearings failing. Combined with the metal shavings found the last time I drained the gear oil, and I'd say the thing is toast.*
My father-in-law wants to help me rebuild it, and if I do I'll be sure to post pics. But does anyone know where I might be able to find a used angle gear for a 2001 V70 XC? Can't really drop $1750 just for the part right now...
2006 Hyundai Sonata (manual trans., surprisingly fun to drive)
2001 Volvo V70 XC (family car)
1989 Volvo 240 DL Wagon (still wheezing)
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RIP:
1988 Izuzu Trooper (manual trans., fuel system failure)
1990 Volkswagen Passat (manual trans., blew head twice)
1989 Pontiac Bonneville (rusted out underneath)
1984 Volvo 240 DL (electrical gremlins)
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