Once I had it apart, I chamfered the edges as described in the TNN.
Before I sealed it back up, I drilled a hole and tapped the bottom of the case for a drain plug. Note that I flattened and smoothed the case for a good seal. That took a bit of work on a flat surface. I used a diamond stone that I use for plane bodies and chisels, but any flat surface would do, and then an absolutely square/orthogonal hole is required for good sealing.
Here it is all put back together. I used the genuine Volvo Anaerobic sealant, new bolts and new seals, all provided in the kit I got from IPD.
Look closely, you can see the flat and the drain plug (14mm thread, gold plug magnetic drain plug). The thickness of the case only provided for about 3 threads, so I didn't torque it very tightly. I had a helicoil standing by to reinforce the threads, but so far, that's not needed.
Now, before it went back in the car, I replaced the collar spline...not easy, I had to grind out a flat notch to get enough purchase on the collar to lever it out. You can see the grinding here:
This is the collar before it came out. Ugly with rust, but, pleasantly, not stripped, or damaged that I could see.
Current Fleet:
2016 Tundra Crewmax 4WD 1794
2005 MB S600 (126K, Michelin AS4, HPL 0W40)
2005 MB SL600 (55K Michelin AS4, Mobil 1 0W40)
2004 V70R (143K, six speed M66, HPL 5W40)
2004 XC90 (235K, HPL 0W30 Euro)
2002 V70-XC (295K, HPL 0W30 Euro)
2002 V70-T5 (225K, IPD bars, Bilsteins)
2001 V70-T5 (125K, IPD downpipe, cat back and other mods)
1932 Packard Sedan (straight 8, dual sidemounts, original paint and interior, Shell Rotella 15W40)
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