Oh dear, angle gear!

[Dangerous Dave]

Well, its ££££ed.

Went round a bend at some traffic lights today, and there was a bang and then some nasty noises.

Got the car up on the ramps and removed the propshaft to eliminate it, and now the angle gear is making some lovely gear grinding noises!

Anyone got a spare one for sale?

[Tomcat]

Aw crap mate, sorry to hear it, try Salvo, Readview, Nads etc to see if they're breaking any.

[Dangerous Dave]

Cheers buddy, I've had a look around, and theres a few options available, I'll just see what turns up.

Gonna remove the angle gear tomorrow and hopefully be able to run without it.

[Tomcat]

Good luck with it, keep us informed....:smile:

[AlanG]

Sorry to hear that Dave,you never know the minute. Good luck in the cure..:B_thumb:

[Dangerous Dave]

<<<<UPDATE>>>>

So today I got home and started to remove the angle gear (which is a PITA to do). Everything was fine until I came to undo the top bolt holding the angle gear on, which cannot be accessed straight on by a socket and ratchet, but has to be undone with a spanner. After finding a spanner to fit in the tiny space, the head of the bolt rounded off as this bolt for some reason is extremely tight (dunno why, it can only be tightened with a spanner too), and I spent the next two hours trying to get it out (including many profanities). I tried everything from hammering a smaller socket on, to welding a socket to it. In the end I welded a huge blob of molten metal to it, and used a larger spanner to release it (followed by a triumphant howl!).

And then I had to undo the steering rack pipes (as really volvos originally are designed as a LHD car, and being RHD everything is in the way) and fumble the angle gear out onto the floor.

The angle gear has no play in it whatsoever, its absolutely crack on. But the connecting sleeve however is shagged (literally). The sleeve's splines are worn down, and the splines in the gearbox are non existant too.

So it looks like a new connecting sleeve, and worse, a new gearbox (or at least a new diff).

A few piccies for those who are interested....

Angle gear removed (finally)
http://i150.photobucket.com/albums/s101/bomb192uk/angle%20gear/15082009152.jpg

Connecting Sleeve
http://i150.photobucket.com/albums/s101/bomb192uk/angle%20gear/15082009154.jpg

Connecting sleeve splines (note worn edges, then at the end, the way they should be)
http://i150.photobucket.com/albums/s101/bomb192uk/angle%20gear/15082009153.jpg

Gearbox output (note worn splines, worse than the connecting sleeve). These two together were causing the gear grinding noise.
http://i150.photobucket.com/albums/s101/bomb192uk/angle%20gear/15082009157.jpg

So really this is the weakest link in the awd drivetrain, as the angle gear is way too big to wear, the smaller connecting sleeve just can't handle the torque and the splines strip.

So now I have put the angle gear back in (as it covers the oil seals and I don't want any more crap in there) minus the connecting sleeve (only took me an hour an a half to put it all back, oh and I started it all at 4pm) and it is fully driveable as a FWD car.

And now I've to try and source some new bits. Lovely.

Hope you've enjoyed my ramblings, and I'll update when I can

Bomb

[AlanG]

Ouch!!

[Dangerous Dave]

Indeedy

'Its ££££ed' is an understatement

Although, I've not seen this on any forum before, not many people have posted on stripping the awd system down (though I guess they've broken cars before, but not really tried to repair them), so I'm venturing into the unknown woooooo