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  1. #1
    Join Date
    Nov 2009
    Location
    New England USA
    Posts
    75

    Default Angle (bevel) gear box

    Hi everyone,
    We have a 2004 XC70 with 210,000 miles.

    We love it, but the mechanic said that we’d have an angle gear problem soon. There is evidence of an oil leak from the angle gearbox on the undercarriage plastic cover (for a long time), but never seen it on the ground. Also I hear a very slight hissing noise (only when I drive slowly, we replaced all four wheel bearings).

    Is there any other symptom I might have? When do I have to OH or replace it? I believe that the dealer cost would be as much as buying a newer used car.

    If I find a used angle gear box, is it hard to replace it? (I have access to a lift)
    Also I cannot find any clips that shows how to add the angle gear oil, is it easy?

    Any other suggestions?

    Please advise.

    THANK YOU AS ALWAYS!!

  2. #2
    Join Date
    Apr 2017
    Location
    San Diego
    Posts
    182

    Default

    I've never replaced it, but I can't imagine it's that difficult. I don't think there's any special alignment needed. Adding oil is easy. There's a fill plug that you remove and pump the oil through. The plug is pretty obvious. It's not a typical fill until it spills out of the hole situation. The factory method is to fill until the oil spills out of the hole and then remove 200 mL. (I made a note to fill with 700 mL in my log book, so it must have taken around 900 mL to spill out of the hole when I did my first change.) Getting the oil out is harder. You need a pump that can suction because you suck it out the fill hole. There is a modification to add a drain plug by drilling and tapping the case if you're so inclined. If you bought it used, maybe it's already been done by a previous owner. I believe Volvo instructed mechanics to add the drain plug.

    Brett
    Last edited by Brett San Diego; 05-11-2020 at 04:55 PM.

  3. #3
    Join Date
    Feb 2013
    Location
    Boston, MA
    Posts
    1,196

    Default

    The leak is common, Volvo has TSB for angle gear reseal: https://www.matthewsvolvosite.com/an...-leak-fix.html

    Removing is not too hard, just have enough ratchet extensions and U-joints for top 2 bolts.

    I would recommend replacing the collar sleeve at the same time. You may find it already stripped. When collar sleeve strips, it damages the splines on angle gear. If that happens I'd get an used angle gear with good splines.
    2002 V70 (sold)
    2005 XC70 (Telos Road took it. Did a chassis swap)
    2016 XC60 (sold, P.O.S.)

  4. #4
    Join Date
    Feb 2010
    Location
    Virginia Beach
    Posts
    4,116

    Default

    This is what you need to do: https://www.volvoxc.com/0/resources/...%20Leakage.pdf

    $200 in parts, including sleeve and a bit of labor, or wait until it blows up and realize that you can't get one anymore, best case, you're looking at $1,800 for a used unit.

    Read through this thread. I did the repair a few years back and added a drain plug. The angle gear on my wife's XC, with 256,000 miles, is clean, dry and functioning perfectly.

    https://www.volvoxc.com/forums/showt...fication/page2

    Hope this helps.
    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)

  5. #5
    Join Date
    Feb 2013
    Location
    Boston, MA
    Posts
    1,196

    Default

    Quote Originally Posted by Astro14 View Post
    or wait until it blows up and realize that you can't get one anymore, best case, you're looking at $1,800 for a used unit.
    Got a leaking one for $350 from a car w/ 100k miles on odo, but with perfect splines. $1800 is for a new (factory-rebuilt) angle gear.
    2002 V70 (sold)
    2005 XC70 (Telos Road took it. Did a chassis swap)
    2016 XC60 (sold, P.O.S.)

  6. #6
    Join Date
    Feb 2010
    Location
    Virginia Beach
    Posts
    4,116

    Default

    Quote Originally Posted by vtl View Post
    Got a leaking one for $350 from a car w/ 100k miles on odo, but with perfect splines. $1800 is for a new (factory-rebuilt) angle gear.
    So...let it blow up?

    Or fix it for less than the cost of a junkyard unit?

    Remember that the OP merely has a leak. You got a leaking one for $350. So, for $350, you got to where he is now: an angle gear resealing job.

    He should just reseal it...before he has to go try and source an already leaking one and spend more money than he would spend to fix his.
    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)

  7. #7
    Join Date
    Apr 2017
    Location
    San Diego
    Posts
    182

    Default

    Practically speaking, a slow leak is merely a nuisance. If the case isn't draining to dryness in short order, you can just keep it topped off and keep on trucking as long as you want. But, you do have to monitor it. You can't just ignore it, or it will be come more than a nuisance.

    I'm a little mystified about the chamferring of the edge of one side of the case. How does that stop any leaking? Seems it's more about the sealant. Is there a defect in casting or machining such that it has a raised edge on the inside?

    Brett

  8. #8
    Join Date
    Aug 2017
    Location
    Pleasanton CA USA
    Posts
    486

    Default

    I had the same 2004 XC70, and the angle gear box had gear oil seepage through the casing seam. There was not any oil deposit on the stone guard, so I took that as a good sign that the gear box retained its supply of lubrication. At 110,000 miles, I serviced the angle gear with new gear oil. Getting the steel plug to unscrew takes some force, but it's easy after that. , and I benefited from a DIY video.

    Your issue is whether your gear oil became depleted thru leakage. You'll know when you go to pump out the old oil -- how much volume comes out?....any metal chaff mixed in with the oil? (There should be 0.45 to 0.65 liters of gear oil that comes out.)

    This vid shows how to remove the angle gear housing should it need to be replaced. https://www.youtube.com/watch?v=4gRSQozsluQ
    2013 XC70 T6 Flamenco Red (hers)
    2015 XC70 T6 Seashell Metallic (his)
    past: 13 Volvos going back to '74 242 sedan

  9. #9
    Join Date
    Feb 2010
    Location
    Virginia Beach
    Posts
    4,116

    Default

    Quote Originally Posted by Brett San Diego View Post
    Practically speaking, a slow leak is merely a nuisance. If the case isn't draining to dryness in short order, you can just keep it topped off and keep on trucking as long as you want. But, you do have to monitor it. You can't just ignore it, or it will be come more than a nuisance.

    I'm a little mystified about the chamferring of the edge of one side of the case. How does that stop any leaking? Seems it's more about the sealant. Is there a defect in casting or machining such that it has a raised edge on the inside?

    Brett
    I don't know the reason for the chamfering. I followed the TSB and the angle gear went from being wet to being dry.

    So, without knowing the reason, I will say that it works.

    At over 250,000 miles, the XC angle gear is tight and dry. With my drain plug mod, I can change the gear oil easily.

    Lots of things on this car wear out easily, lower control arm bushings, engine mounts, for example, but the engine itself, and this gear, will last forever if properly lubricated. At 250,000+ miles, the car still runs great.
    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)

  10. #10
    Join Date
    Feb 2013
    Location
    Boston, MA
    Posts
    1,196

    Default

    Quote Originally Posted by Astro14 View Post
    So...let it blow up?

    Or fix it for less than the cost of a junkyard unit?

    Remember that the OP merely has a leak. You got a leaking one for $350. So, for $350, you got to where he is now: an angle gear resealing job.

    He should just reseal it...before he has to go try and source an already leaking one and spend more money than he would spend to fix his.
    No, I just pointed out that used AG is far less than $1800.

    Mine was "grade A" bought at erievolvo@ebay, it was supposed to be in the top notch shape for a used unit. However, I needed my car back on the road quickly, and I had everything to do the full AG rebuild, including new bearings. The seller agreed to take back the unit taken apart if I find it damaged from running dry. It was good though.

    Resealing AG is not hard at all.
    2002 V70 (sold)
    2005 XC70 (Telos Road took it. Did a chassis swap)
    2016 XC60 (sold, P.O.S.)

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