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AWD not working after hearing snap from rear end S60 2004

posted by  buckley_49620 on  Sat Feb 19 18:15 CST 2022
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last visit: Thu Jan 23 08:19 CST 2014
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Hi all, I was approaching a stop sign on a slippery road, the ABS activated and the car came to a stop. I took my foot off the brake pedal and started to accelerate, the car made a snap sound and I felt it. After I made the turn and tried to get going I only had FWD, I took it easy the rest of the way home (about 120 miles) on slick roads and snowing hard.
When I got home in the driveway I stepped on the gas and only have FWD. I have never changed the fluid or filter in the rear dif and the car has 229K on the clock. I have pulled my snowmobile with this car some but not very far. I know that I have neglected the rear dif and now I have to get into it.
Any ideas and past experiences of what I need to do would be a big help.
Thank you all
Gene








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    posted by  someone claiming to be on  Wed Dec 31 18:00 CST 1969 [RELATED]

    Start with the Coupler between the Transmission and the front angle gear In snow belt areas these fail from rusting splines. I had to replace one on My 05 XC90 for the same reason a loud noise the no AWD. AKA Salt belt cars. My friends son works at their Volvo shop and has replaced around 40 of these. usually when the rear section fails there isn't any loud bangs it just doesn't work.
    Hope this helps,

    Rule of kiss start with the easiest simplest 1rst


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    posted by  someone claiming to be on  Wed Dec 31 18:00 CST 1969 [RELATED]

    It's too bad the rest of us didn't hear the sound, it would make diagnosing easier :)

    The Haldex unit is very close to your right foot. It is supposed to be serviced at 50K intervals, so I guess you got your money's worth. Repair is not worth the cost as I assume that the transfer case is probably also shot.

    --
    Keeping it running is better than buying new



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      posted by  someone claiming to be on  Wed Dec 31 18:00 CST 1969 [RELATED]

      KlausC I hoped you would see my post ,
      Is the Haldex unit on the transmission, and can it pe replaced or do i need to replace the trans ?
      This is my first AWD and I have never been into the driveline of a AWD Volvo. Is it a rebuildable transfer case ?
      Thanks again
      Gene



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        posted by  someone claiming to be on  Wed Dec 31 18:00 CST 1969 [RELATED]

        Forget rebuilding the transfer case, getting a used one is a crap shoot. So it is tranny - transfer case - Haldex - rear prop shaft - differential.

        A host of things can go 'snap' and the only way to find out is on a lift. You can look for Haldex repair and see what that is about. Differentials are almost indestructible. A rear half shaft could break?? You need a lift and a GOOD mechanic, not just somebody with a scan tool.

        --
        Keeping it running is better than buying new



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          posted by  someone claiming to be on  Wed Dec 31 18:00 CST 1969 [RELATED]

          I have read some post that the angle gear sleeve can strip out and that will disable the AWD. This car was dealer serviced until around 160k and is in good shape for the milage, si I think it is worth saving to drive in the winter
          I will know more tomorrow when I get it on the hoist and check it out more. Right now my sons Subaru is on the hoist waiting for rotors.
          Thanks again
          Gene



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            posted by  someone claiming to be on  Wed Dec 31 18:00 CST 1969 [RELATED]

            Dealer service means nothing to me after the car reaches 50K miles. Few dealers service Haldex units, flush trannies, or antifreeze in a timely fashion.

            Yes, the rear drive spline in the xfer case can get stripped, usually when over revving and then hitting dry pavement with full grip!

            A broken rear axle can also cause the rear diff to spin and not move the other wheel. A 'snap' in the rear could have been a broken clamp allowing the axle to slip free of the diff??

            Spoke many possibilities...
            --
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              posted by  someone claiming to be on  Wed Dec 31 18:00 CST 1969 [RELATED]

              I would guess if the rear drive spline stripped, I can have the car on the hoist in park and the drive shaft will turn a rear wheel?
              The only time I am getting the traction light is when one of the front tires slips on ice.
              I really thank you for the information



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                posted by  someone claiming to be on  Wed Dec 31 18:00 CST 1969 [RELATED]

                This happened on my 2005 XC70. I tried to aggressively pull into traffic from an icy parking lot. The AWD worked, then hit dry pavement. I heard the "pop" sound that I think you are describing. No more AWD. Turned out that the angle gear had stripped, as Klaus suggested. I am not an angle gear fixing kind of guy, so my independent Volvo mechanic fixed for about $700. Lesson learned about aggressive treatment of the AWD system.



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                  posted by  someone claiming to be on  Wed Dec 31 18:00 CST 1969 [RELATED]

                  I still have not had time to get into in yet



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                    posted by  someone claiming to be on  Wed Dec 31 18:00 CST 1969 [RELATED]

                    Well after months of my S60 sitting I finally got the time to tear into it and see what was the issue with the AWD. After pulling the angle gear box/transfer case I found that the coupler between the transmission and AGB was stripped in the AGB side. I had already bought the coupler kit from the dealer, so I did not have to chase any parts. I did have a good set of micrometers that I could check the input splines on the AGB and could not find much wear, but the coupler was very rusty and compared to the new coupler was totally warn on the AGB side.
                    The time to replace the coupler was just over two hours and really not that bad of a job. I did this on a hoist so that made it easy to do all the under car work. No need to pull the rear drive shaft, the AGB will move out of the way giving plenty of room to remove the coupler. Removing the two bolts on the upper knuckle too the strut gave me enough room to get the axle shaft out of the car and again giving me the room to get the axle out of the way.
                    I really want to thank all the response to this post with the info from all of you, it helped me doing this job
                    Gene



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    posted by  someone claiming to be on  Wed Dec 31 18:00 CST 1969 [RELATED]

    I am one of Brickboard members that have a great relationship with my dealer.

    I would have a good Volvo dealer troubleshoot the problem ASAP.

    The most that many dealers charge is one hour's labor. It might be a simple issue.

    Many who have had AWD troubles just disconnect the rear driveshaft. Perhaps the Diff as well, maybe a computer reprogramming to avoid trouble lights. However I think that removing the driveshaft is enough.

    I happen to own a base '12 XC70 with front wheel drive (a replacement for V70s). It dos however, have the same rear suspension as an AWD car except for a diff and axles.

    BTW - This new '12 XC70 only cost me $29,900 less $1000 loyal bonus and $900 of for the first 3 payments (we paid cash).

    Regular XC70s were more than $16,000 more.

    A new Volvo for less than a used rice burner.



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