Service

If the leak is confirmed to be coming from the rear differential housing halves, separate and reseal the rear differential housing according to the following procedure in conjunction with the removal and replacement procedures in VIDA.

1. Note! Some variation in the illustrations may occur, but the essential information is always correct.

Final drive, removal

2. This method applies to all final drives with a 45° mating flange.

Remove the final drive from the vehicle according to VIDA:

INFORMATION

REPAIR

Removal, replacement and installation

Power transmission

Rear axle, drive shafts

Final drive

Drain the oil from the final drive.

General (applies to all models)

3. Warning! Use protective eyewear.

Clean the final drive using isoproponal PN 1161721 around the mating flange.

Blow clean with compressed air.

Remove:

- The screws, quantity (qty) 8 or 9, depending on model.

Final drive, cleaning

4. Clean the oil from the flange using isoproponal PN 1161721.

Clean all gasket material from the flange using gasket remover PN 1161847 and abrasive cloth PN 9511024.

Note!
Use the abrasive cloth along the flange as the arrows indicate.

Clean the flange using isoproponal PN 1161721.

Caution!
Ensure that gasket residue does not end up in the final drive.

5. Cover the opening in the case with masking tape.

Countersink the surface at the bleed hole to prevent the hole from becoming blocked by sealing compound. Use special tool 9814112.

Check that the hole is open with 1 mm (approx 1/32") welding rod or similar.

Cover, cleaning

6. Clean the oil from the flange using isoproponal PN 1161721.

Clean all gasket material from the flange using gasket remover PN 1161847 and abrasive cloth PN 9511024.

Note!
Use the abrasive cloth along the flange as the arrows indicate.

Steps 7-9 apply only to S40/V50

7. Remove the filter on the bleed nipple.

8. Remove the bleed nipple. Use a mandrel and a hammer.

9. Countersink the surface at the bleed hole to prevent the hole from becoming blocked by sealing compound. Use special tool 9814112.

10. Measure 3 mm (approx 1/8") from the inside of the flange and make a line with a permanent marker.

Note!
This procedure can be made easier by making a template which can be reused for several repairs.

Note!
General illustrations were used for steps 10, 11, and 12, but the method is the same.

11. Caution! Care must be taken to avoid damage to the bearing race while filing. A coffee cup can be used to cover the bearing race.

12. File off the inner edge of the cover as illustrated, approx. 3 mm (approx 1/8").

After filing, polish the chamfer using a fine emery cloth so that scoring in the chamfer goes along the chamfered edge.

Note!
Use the emery cloth radially, along the flange just as the arrows indicate.

The finished product should look like this.

13. Remove the seal.

Warning!
Use protective eyewear.

Clean the cover and blow clean using compressed air.

Note!
Ensure that there are no metal filings in the cover.

S40/V50 only: Install the bleed nipple and filter.

14. The mating surface between the cover and the final drive housing is narrow at certain places.

There are 2 critical areas, see the arrows. It is important that the sealant bead is applied correctly at these locations.

Apply a short bead of sealing compound at these locations only and install the cover. Remove the cover and check that the bead is not outside the cover's mating surface. Wipe away the sealing compound and clean using isoproponal PN 1161721.

15. Applies to covers on all vehicles: Apply a 1.5 mm (approx 1/16") bead of sealing compound to the cover.

16. Applies to XC90: Apply a bead of 2.0mm (approx 5/64") sealing compound as illustrated.

Note!
Note where the bead is to be applied at the arrow.

17. Steps 17 and 18 apply to XC70/V70/S60: Mark up the mating surface for the cover using a marker pen.

18. Apply a bead of 2.0mm (approx 5/64") sealing compound as illustrated.

19. Applies to S40/V50: Apply a bead of 2.0mm (approx 5/64") sealing compound as illustrated.

20. Applies to all vehicles: Request the assistance of a colleague to align the differential housing and install the cover.

Tightening torque, 29 Nm (21.4 lbf-ft).

Seal ring, installation

21. Install a new seal ring (removed in step 13) according to VIDA:

INFORMATION

REPAIR

Removal, replacement and installation

Power transmission

Rear axle, drive shafts

Drive shaft

Oil, filling

22. Fill with oil according to VIDA:

For oil filling, see:

Removal, replacement and installation

INFORMATION

REPAIR

Power transmission

Rear axle, drive shafts

Center differential

Final drive, replacing

Final drive, installation

23. Install the final drive according to VIDA:

INFORMATION

REPAIR

Removal, replacement and installation

Power transmission

Rear axle, drive shafts

Center differential