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My angle drive coupling and bevel gear have gone on my S60R. This means $$$$ and Volvo Canada won't cover any of it. Does anyone know where I can get a hold of a coupling and/or the center splined shaft in the angle drive. The entire angle drive is fine but Volvo will only sell the unit as a whole, although they will refurbish the one out of my car by replacing the center shaft and sell it to the next guy for the price of an entire unit.
Please Advise!
Dave
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his information is not entirely correct. There was no change to the power handling capacity of the haldex unit in 2006. The change in 2006 changed the time required for the haldex unit to engage the wet clutch pack. The engagement in the 06+ model years is MUCH faster and the pack has the ability to engage with more force from a standstill. We have discussed the matter directly with Haldex and nothing substantive changed over the Rs production.
The bevel gear is rated for 1,000nm as are the splines on the input shaft. This unit is made by Getrag for Volvo. The engine's maximum output is 400nm, so even accounting for loading and shock, 1,000mn is fairly reasonable considering it is receiving 1/2 the power. Remember there is no open diff in the centre of the R, the front and rear power outputs are tied together inside the transmission. There is a diff between the front L & R wheels and the rear L & R wheels and the Haldex Active On demand Coupling (AOC) acts as the centre diff allowing the front and rear wheels to spin at different rates.
The problem with the splines stripping on the angle gear are caused bu the collar gear having a VERY poor fit. If you look at the thread we started on the analysis of the collar gear there is a diagram of the poor fit. The collar gear splines mate with the input shaft splines on the bevel gear for only a small portion of the tip of each spline, this is a less than idea arrangement and leads to premature wear and failure. At the least a better fitting part would relieve much of this issue. In the analysis of the part the failure mode is this:
1. The part is ill fitting from the factory, knowing this Volvo injects epoxy into the collar gear before fitment.
2. The poor fitting gear causes the expoxy to crack and fail
3. The collar gear being subjected to the AOC coupling/decoupling the rear wheels causes the ill fitting splines on the collar gear and the bevel gear input shaft to "bang" into one another.
4. The play in the collar/input shaft increases as the collar gear deforms and wears the input shaft splines
5. When the deformation and wear is sufficient, the weakened splines on the collar gear give way
6. The splines from the collar gear wear the input shaft down as the now failed unit spins around the input shaft.
7. The longer one drives with the failed AWD the worse the wear becomes.
I would want to see the SAE J500 doc and what documentation he found to support his claim "According to the SAE J500 document, the torque change in 06 gets the torque through the shaft/coupling at about the minimum SAE standard" SAE does not document changes to individual model cars and their drivetrains, so I'm not sure how he arrived at this conclusion. SAE J500 just defines fitment specs and load ratings for splined interfaces, it is by no means definitive and by no means a requirement for anyone to use it.
Those guys know their stuff! Here's the link:
http://www.v70r.com/forums/index.php?showtopic=17503
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My name is Klaus and I am a Volvoholic.
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The shaft and angle gear should be the same for all Volvos. Scour the salvage yards close to you for S60, S80, XC70 and V70R.
I asked Howard to chime in, but his bevel gear just slipped down the shaft without too much damage. I believe he just glued the angle gear back in place.
You are correct about it being too fragile. It has been this way since 1997 and the addition of 300bhp doesn't help any. You just talked me out of buying an AWD for my daughter :) I just appreciate the additional safety in slippery road conditions.
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My name is Klaus and I am a Volvoholic.
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Just checking up on this - not questioning, just trying to be certain I'm clear.
You're saying the angle/bevel gear has been the same part since they started doing AWDs?
I'm pretty sure the first real AWD model with a decent sized production run and everything was the 1998 V70 AWD /V70 AWD XC. (I don't remember if there were 850 AWD wagons available to the public or not, or if they were maybe only available in the UK, or what...)
I was pretty certain that the 1998, 1999, 2000 models that had AWD all used the same setup, and after that the drive engagement mechanism changed - in those early cars it was a rather simple viscous coupling, and after that they changed to a Haldex system.
So the angle/bevel gear stayed the same even when they changed to the newer Haldex systems?
Is it still the same angle/bevel gear now in the newest models (the new-for-last-year V70s/etc) ?
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1998 V70 AWD Turbo 180k+
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AWD was intorduced to the world, minus usa, in 1997. The early models did not have a splined shaft, the new ones apparently do.
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My name is Klaus and I am a Volvoholic.
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What a real bummer. If you were USA, I would have suggested Erievovo.com as a good place to call for a replacement.
If there is a gear shop close to you, they could probably repair it. The angle gear is pressure fitted to the shaft and it sounds like it came loose. A board member once took his angle gear box apart and found that same situation. He and his trusty mechanic just put it back in place.
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My name is Klaus and I am a Volvoholic.
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I have already removed the angle drive and found that the press fit sleeve along with mating serrated shaft are both stripped. I was hoping to buy each of these parts and save myself from having to purchase the entire angle drive (volvo dealer repair). It looks as if this isn't going to be possible. Thanks for the link though. I will be sure to check it out for parts in the future.
As it turns out, Volvo appears to have designed the serrated shaft to SAE document J500. I have a chart of the Torque capacities and am sorry to say that although the S60R angle drive torque capacity sounds high [~9000 in*lb], a quick look at the loading on the angle gear in a wet pavement situation implies that the serrated shaft is a real achillies heel and would easily break after jsut a few high impact cycles.
When reading this it is important to note that the S60R produces 300 ft*lb of torque in*lb]. A MINIMUM impact loading for this would create a factor of 2 {every time you make the car move}. You can see that it wouldn't take much wet to really start to damage the gear, especially after many fatigue loadings.
It should be noted that this SAE spec was canclled in 2000.
Dave
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I just checked with a fellow in England/Scotland (Isle of Skye) about his "fix":
" It was not me that had the bevel gear come loose, but I did send you a posting off another forum, from a guy that found his AWD was only FWD when he towed his caravan out of a muddy field!!
I was shocked to learn that it was not SPLINED...
I doubt very much if 'creative' workshop metheods would provide a good enough repair, but it might in some cases, depending on how slack it had become on the shaft, and how good the meshing still was .
There is a very heavy grade of Loctite (shaft repair) that I have used on the trawlers in 'shit or bust' situations to good effect.
I might use that, then put a couple of blobs of weld on , MIGHT."
Take it for what it is worth, it sounded good at the time :)
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My name is Klaus and I am a Volvoholic.
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I looked at the serrated shaft and coupling linking the angle drive to the transmission. both had the teeth worn. Volvo Halifax gave me a bit of a deal on the service but it was still a $3200 fix. Anyone else getting this fix should note that it is only half the solution. When you get the shaft and coupling replaced, get NEW parts. They have more engagement then the old ones. You should also get Volvo to update the software in your Haldex unit. Volvo limited the rear torque to 1000 N*m for the 06 and up models. The Updated coupling has only been around for about the last 15 months (According to Volvo). According to the SAE J500 document, the torque change in 06 gets the torque through the shaft/coupling at about the minimum SAE standard. I believe that with both fixes, the $$$$ angle drive and the fairly cheap (~$100) Haldex software upgrade, you should be safe to drive your AWD Volvo. Hope this Helps.
Dave
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I am sorry it happened to you, but glad you shared the info with us. I was unaware that the system was redesigned for 2006. I will make a note and let others know about this problem.
If you don't mind, I will share your findings with the folks on V70R.com
Klaus
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My name is Klaus and I am a Volvoholic.
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