P80 AWD repair advice needed

GreenGL

I've decided to try to repair the AWD system on my P80 V70XC.

I will be going on some camping trips in the not too distant future so working AWD would be handy, and I like to have as many original features in my cars working as possible. I don't think I will be hitting rough enough terrain to upgrade to a 4x4 or even a XC90.

I've bought the car with no tailshaft, I have sourced one in the interim. I've been told by a mechanic that my angle gear is stuffed. I will need to get it rebuilt, or replaced. Problem is, there seems to be several different angle gears through the P80 run. My car is a 1999, I have a spare from a 1997 but apparently this will not fit my car? And the output stub shaft length is different to mine.

Is it worth trying to rebuild the angle gear on my car? Or is it best to try to find a good matching replacement. Angle gear has to come off so I can fix the leaking turbo drain seals.

I will worry about the Viscous coupling once I've sorted out the angle gear, at least there is only 2 types of VC in the P80 run.

Philia_Bear

You do understand the awd system is mostly useless in anything but snow?

Good tyres inflated correctly will do more than the awd system off road

The angle gear is easily rebuilt

The issue is the interference fit of the gear on the hollow shaft is weak so the gear starts spinning

Shaft into lathe

Turn down shaft

Make up a slip ring with Max interference fit possible

Cool shaft and heat ring using oven and liquid nitrogen

Mate

Turn down ring for fitment with ring gear

Heat and cool again and plan to use a 20ton press

I did try welding a shaft for a build up but it got out of round enough that I said screw it

Not one of these fail a second time for the ones I have done

More common is the Coupler by far

GreenGL

Philia_Bear
You do understand the awd system is mostly useless in anything but snow?
Good tyres inflated correctly will do more than the awd system off road
The angle gear is easily rebuilt
The issue is the interference fit of the gear on the hollow shaft is weak so the gear starts spinning
Shaft into lathe
Turn down shaft
Make up a slip ring with Max interference fit possible
Cool shaft and heat ring using oven and liquid nitrogen
Mate
Turn down ring for fitment with ring gear
Heat and cool again and plan to use a 20ton press
I did try welding a shaft for a build up but it got out of round enough that I said screw it
Not one of these fail a second time for the ones I have done
More common is the Coupler by far

Have seen some people overseas playing in the mud with them. And I'd do a bit of snow when snow season hits here.

You say good tyres> working AWD. What tyres would you put on a v70xc?

I'll see if I can find someone local with a lathe, after I confirm my coupler is still ok

GreenGL

Philia_Bear

You feel like fixing/upgrading another angle gear?

Mine needs to be done.

Philia_Bear

GreenGL
https://ozvolvo.org/discussion/comment/217181#Comment_217181
Have seen some people overseas playing in the mud with them. And I'd do a bit of snow when snow season hits here.
You say good tyres> working AWD. What tyres would you put on a v70xc?
I'll see if I can find someone local with a lathe, after I confirm my coupler is still ok

These are what I run on my FWD only XC's

jamesinc

@GreenGL, @Brehon47 has a viscous coupling for sale that may be of use to you

GreenGL

Philia_Bear
https://ozvolvo.org/discussion/comment/217264#Comment_217264
These are what I run on my FWD only XC's
https://cdn.ozvolvo.org/uploads/9ONY7I1Y2MB5/image.png
or
https://cdn.ozvolvo.org/uploads/7FEBQ3DZNCC9/image.png

Did you get much if any scrubbing with those size tyres?

And how much of a lift do you run, if any?

Philia_Bear

Side note

Chains or snow socks on 2wd is more effective than 4wd with STD tires

Mud wise.... with the viscous coupling requiring spin from the front to put any power to the rear.... its less than ideal

The haldex systems do better.... as found in the xc90 and the p3 xc70

Fitting a LSD to the front would also make an overall larger difference than fixing the 4wd system

Philia_Bear

Those are factory size 16s

No extra lift

Have installed skid "plate" to the underside of the subframe to better protect the oilpan

GreenGL

Philia_Bear
Those are factory size 16s
No extra lift
Have installed skid "plate" to the underside of the subframe to better protect the oilpan

What year are your V70XC's?

Mine is a 1999, P80 Chassis. Owners manual states 205/55/R16, same as what is on my car, speedometer is just about accurate.

I think the early P2 XC ran bigger tyre sizes, which is easier to find A/T options in.

Philia_Bear

Yeah confused p2 and p80

1999 P80 based xc70 was factory 215/55r16 or 205/65/15

Lots of good winter tyre options for 215/55r16

Nokian makes most of the best options

GreenGL

Long time since updating.

I finally found the time and the room to investigate the issue further.

With car in P (Auto gearbox) and front wheels off the ground, turning the angle gear output flange by hand had no effect on the wheels. Turning wheels had no effect on the angle gear flange.

Pulled the angle gear off the gearbox, found the angle gear collar had stripped splines on the output side, and the angle gear input splines also stripped.

Pics aren't the best but might be enough to give you an idea.

Anyone here have a contact of someone , ideally Melbourne based who can rebuild these angle gears? Possibly stronger than what Volvo did,

Ex850R

Berrys have a shop that fixes Haldex input so it’s strong, maybe they can do it OR get an industrial shop to do it, it’s what they do.
I’ll find who does the work for where I am at Visy engineering maintenance

GreenGL

Ex850R

If you can pass me a contact that would be great.

I'll see if I can find out who BMG uses .

Ex850R

GreenGL
Hej Man ask Mark , he told me once but i forget my own TRADE at times so dont ask me.....
He jsut had his missus XC90V8 Haldex input bearing done with larger one so i rekon they will be good.