Drivetrain/A/T - Axle Frost Plug Leaking/A/T Issues

Retailer Technical Journal 7319

Left front axle frost plug, Missing or displaced

XC90 T6 only

Date 09-11-2009

Reference: VIDA, VSTG, RTJ 16773

NOTE If using a printed copy of this Retailer Technical Journal, first check for the latest online version.





AFFECTED VEHICLES

DESCRIPTION:

When diagnosing an oil leak from the left front axle, a transmission shifting complaint, or a Diagnostic Trouble Code (DTC) set in the Transmission Control Module (TCM), it is important to check that the frost plug inside the axle has not fallen from its location. When the frost plug falls from its location, axle grease can mix with automatic transmission fluid (ATF). See photo below. Note that it is not always this obvious and there are two ways to check if axle grease and ATF are mixing.





SERVICE:

There are two checks to see if the frost plug has fallen from its location. If the frost plug has fallen (on earlier manufactured axles) axle grease mixed with ATF will leak from the bolt hole in the axle for the hub-to-axle attachment bolt. Remove the hub-to-axle attachment bolt and check for this. See photo below. This only applies to early axles.





On later axles, the axles are not drilled through and axle grease mixed with ATF will not make its way to the bolt hole in the axle for the hub-to-axle attachment bolt. On later axles, the left front axle must be removed from the transmission in order to check if axle grease mixed with ATF is leaking from the inner side of the axle. Since it is not easy to distinguish between the two versions of axles, both ways must be checked to be sure the frost plug is in place!

If the frost plug has fallen from its location but the transmission shifting behavior is unaffected, replace the axle and flush the transmission and the ATF cooling system (radiator, auxiliary cooler [if applicable*], and cooler lines) with new ATF of the correct specification according to VIDA. See RTJ 16773 for the specified ATF.**

If the frost plug has fallen from its location and the transmission shifting behavior is not OK, replace the transmission, the axle, and the complete ATF cooling system (radiator, auxiliary cooler [if applicable*], and cooler lines) according to VIDA.

Note!
When installing the new axle into the transmission, do not force the axle beyond the snap ring detent as this can damage the transmission and/or the frost plug of the new axle. This includes not forcing the hub onto the axle when installing the hub/knuckle/strut assembly onto the axle.

*Note! All 2003-2005 XC90 T6 vehicles have an auxiliary ATF cooler.

**Note! All 2003-2005 XC90 T6 vehicles use DEXRON III-G or III-H. No other ATF should be used!





WARRANTY CLAIM INFORMATION