XC90 Noisy Diff - Solution found
In a previous thread earlier this year i detailed how my XC90 with over 200,000ks on the clock was starting to get a noisy rear diff. At the time i changed the diff oil and the oil that came out looked like brown metalic paint. The oil change and another one about a month later helped quieten the diff, but was never a solution. The diff had to be rebuilt but with only 1 Volvo specialist within 250km of me i guessed it would cost a bomb.
I spent more than a few hours researching for answers and found out that certain models of Landrovers share the XC90 diff. I approached my local (Bathurst) Landrover specialist to see if he was interested in fixing the diff. He was familiar with the problem and said that Landrover do a sevice kit. The issue is the diff pinion bearing.
Well he had the car for under a week, stripped and rebuilt the diff and replaced the haldex filter etc. The car is now as quiet as a mouse and the cost was just over $2k. I'm over the moon.
Here is the worn out pinion bearing.