Went into my mechanic with my '95 960 wagon (111,000 miles) having an underbody rattle and vibration. He identified a worn CV joint between the drive shaft and axle. He called Volvo and was told the company no longer sells that CV joint and offered the new recommended fix, the entire drive shaft assembly and differential flange (system used in '97 and newer) with a traditional U joint for $1,150.
Does anyone out there have advice on a lower-cost solution? The $1,150 isn't in my family's budget. The mechanic suggests there might be a close enough CV joint match with a replacement for another vehicle. Or he says we might find a '97 or newer used shaft assembly. Or we might find a good used CV joint from the '95 or 96' model years. The other option he's thinking about is machining the end of the existing shaft to take the joint currently specified for the car.
I would greatly appreciate any advice on the best solution and/or where I might find the parts necessary to make the fix in a more economical manner.
My mechanic works mostly on Volvos and he's very disappointed with the answer he got from the manufacturer. He thinks there must be a better answer than replacing the entire drive shaft assembly, which is otherwise in great condition.
Thanks in advance for any help!