Volvo XC90 Haldex AOC Pump Replacement DIY (2003-2008 P2 Volvo XC90, XC70, S60R, V70R)
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- เผยแพร่เมื่อ 3 ก.ค. 2024
- ►Replacing your XC90's Haldex AOC pump is the only way to restore the AWD system after a pump-related failure. The Haldex-based all-wheel-drive system found in modern Volvos is an excellent system with relatively few moving parts. The AOC pump is a crucial component, providing the pressure the rear coupling uses to engage AWD. However, the pump will burn out after extensive use.
A failed pump will prevent engine power from transferring to the rear wheels under slippery conditions. You can test your pump's health by driving on a loose dirt surface and applying the throttle aggressively to create wheel spin in a straight line. If the rear wheels don't engage, then your pump is likely damaged.
In this video, FCP Euro's Professional DIY'er Mike Hidalgo tackles a Haldex AOC pump replacement on a P2 Volvo XC90.
00:00 - Intro
02:43 - Tools Needed
04:15 - System Check
05:22 - Job Start/Exhaust Removal
08:00 - Driveshaft Removal
11:13 - Differential Flange Removal
13:28 - AOC Pump Removal
15:59 - AOC Pump Explanation
17:22 - AOC Pump Installation
20:08 - Differential Flange Installation
21:17 - Driveshaft Installation
23:43 - System Fluid Fill
26:12 - Exhaust Installation
27:00 - Wrap-Up
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Volvo S60 P2 Chassis (Gen 1) - AWD
2003-2006 Volvo S60 AWD Sedan 2.5L L5 VIN:59 B5254T2 Automatic Differential Service Kit
2004-2005 Volvo S60 R Sedan 2.5L L5 B5254T4 Automatic Differential Service Kit
2004-2005 Volvo S60 R Sedan 2.5L L5 B5254T4 Standard Differential Service Kit
2004-2005 Volvo S60 2.5T AWD Sedan 2.5L L5 VIN:59 B5254T2 Automatic Differential Service Kit
2006-2008 Volvo S60 R Sedan 2.5L L5 B5254T4 Automatic Differential Service Kit
Volvo V70 P2 Chassis (Gen 1) - AWD
2003-2004 Volvo V70 AWD Wagon 2.5L L5 VIN:59 B5254T2 Automatic Differential Service Kit
2004-2005 Volvo V70 R Wagon 2.5L L5 B5254T4 Automatic Differential Service Kit
2004-2005 Volvo V70 R Wagon 2.5L L5 B5254T4 Standard Differential Service Kit
2004-2005 Volvo V70 2.5T AWD Wagon 2.5L L5 VIN:59 B5254T2 Automatic Differential Service Kit
2006-2008 Volvo V70 R Wagon 2.5L L5 B5254T4 Automatic Differential Service Kit
Volvo XC70 P2 Chassis (Gen 1) - AWD
2003-2007 Volvo XC70 X/C Wagon 2.5L L5 VIN:59 B5254T2 Automatic Differential Service Kit
Volvo XC90 P2 Chassis (Gen 1) - AWD
2003-2006 Volvo XC90 Base Sport Utility 2.5L L5 VIN:59 B5254T2 Automatic Differential Service Kit
2003-2005 Volvo XC90 T6 Sport Utility 2.9L L6 B6294T Automatic Differential Service Kit
2004-2005 Volvo XC90 2.5T Sport Utility 2.5L L5 VIN:59 B5254T2 Automatic Differential Service Kit
2004-2005 Volvo XC90 T6 Sport Utility 2.9L L6 B6294T Automatic Differential Service Kit
2006-2008 Volvo XC90 2.5T Sport Utility 2.5L L5 VIN:59 B5254T2 Automatic Differential Service Kit
2006-2008 Volvo XC90 V8 Sport Utility 4.4L V8 B8444S Automatic Differential Service Kit
2006-2008 Volvo XC90 V8 Ocean Race Sport Utility 4.4L V8 B8444S Automatic Differential Service Kit
Volvo S80 P2 Chassis (Gen 2) - AWD
2004-2006 Volvo S80 2.5T AWD Sedan 2.5L L5 VIN:59 B5254T2 Automatic Differential Service Kit
Volvo V50 P1 Chassis - AWD
2005-2007 Volvo V50 T5 Wagon 2.5L L5 B5254T3 Standard Differential Service Kit
2005-2007 Volvo V50 T5 Wagon 2.5L L5 B5254T3 Automatic Differential Service Kit
2008-2009 Volvo V50 T5 Wagon 2.5L L5 B5254T7 Automatic Differential Service Kit
2010 Volvo V50 T5 R-Design Wagon 2.5L L5 B5254T7 Standard Differential Service Kit
2010 Volvo V50 T5 R-Design Wagon 2.5L L5 B5254T7 Automatic Differential Service Kit
Volvo S40 P1 Chassis - AWD
2005-2006 Volvo S40 T5 Sedan 2.5L L5 B5254T3 Standard Differential Service Kit
2005-2006 Volvo S40 T5 Sedan 2.5L L5 B5254T3 Automatic Differential Service Kit
2007-2008 Volvo S40 T5 Sedan 2.5L L5 B5254T3 Standard Differential Service Kit
2007-2008 Volvo S40 T5 Sedan 2.5L L5 B5254T3 Automatic Differential Service Kit
2009-2010 Volvo S40 T5 Sedan 2.5L L5 B5254T7 Automatic Differential Service Kit
Volvo S80 P3 Chassis - AWD
2007-2008 Volvo S80 V8 Sedan 4.4L V8 B8444S Automatic Differential Service Kit
2007-2008 Volvo S80 T6 Sedan 3.0L L6 B6304T2 Automatic Differential Service Kit
Volvo XC70 P3 Chassis - AWD
2008 Volvo XC70 3.2 Wagon 3.2L L6 VIN:98 B6324S Automatic Differential Service Kit
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Dude your voice makes all this maintenance sound so easy!
You just made a job dreaded actually fun! Love to see all your videos on the P2 platform!
I just want to say you have no, I when I say no I legit mean no IDEA how much you helped a young mechanic in the Volvo learning industry
Been waiting for a FCP Euro video on this job to come out for YEARS. No more waiting around- I’ll be doing this soon for sure. Tired of that service light! Thanks!
Thank you for your patience!
Awesome video. Great job planning and recording this service. Haldex pump service is not an easy job but you did it nicely.
Thank you very much!
@@fcpeuro There is not enough room to remove the service pump without removing the the prop shaft flange?
made it look easy. good prep and delivery. ty
Glad you liked it!
This good people really likes your video. 😊
Thank you Thank you Thank you for finally posting a properly great video of this process. You made it look easy. Been needing to do this since I bought mine two years ago.
Awesome job,,thanks for the great tutorial,,your 1 of the best to do it,,,🎉
This is the very best video on this topic, well done. Informative and educationally enlightening. Thank you.
Glad you enjoyed it!
FCP is stepping up their DIY game. I welcome all this content. It honestly makes me want to repair stuff that isn’t even broken yet.
Great video, thanks!
Glad you liked it!
Very nice Video 😁👍.
Just like ringing a bell, might as well do the timing belt since your warmed up. Hope your is a 2.9 like mine! Damn pretty work Bud! Thank you!
of course, I'm saying to myself while watching... MY bolts won't come off that easy- nope- I'm 'special'- everything has to be hard for me. Anyway- great video, thank you for doing these.
Awesome👍🏽
FYI
Heavy Touch of Acceleration: floor it
good vid, the exhaust hanger tool is a knuckle saver, $22 amazon.
Really good video. When you use a screwdriver or pry bar to hold the drive shaft flange [any part] from rotating and you position the screwdriver against the socket or bolts that you are tightening you will get an incorrect torque value because of the resistance you are creating with the screwdriver. It might be a few NM or a lot of NM. Try to located the screwdriver on two of the bolts that you are not torqueing. Maybe I'm too fussy but I worked in the aircraft and nuclear industries and learned the importance of precision. Where precision is not necessary then it does not matter for example tightening the wheel nuts on your wheel-barrow or that old trailer that you only use in the woods to transport your fire wood.
Great note, thank you, Peter!
FYI for haldex 4 after filling with new oil, go for a short drive, refill until it drips out and then remove 40ml of oil.
Great note, Jay!
How about just spinning the wheels?
@@ggtaruc2578 needs a little more warm up than that. I was told by a Volvo tech that they drove about a mile.
is this not needed for the haldex 3 system?
Good video,, Swedes made one as well and the original filter cap was totally different.
Does the filter fit both Haldex 3 and 4? Soon to be ordering the goods. Thank you 🙏
Hi I own a 2007 Ford freestyle and it has the exact same setup. I believe the previous owner never serviced the hapdex unit and now it has a howling noise when speed over 40mph and awd light is on. would changing the haldex fluid from howling? I am guessing probably not😢
Is it a good idea to blow compressed air into the fill hole to blow out as much old oil as possible?
Hi FCP EURO, i am confused which one is the filling cap for the haldex gen 3 unit as I am seeing two caps at the side where the haldex controller is?
Is this the process for an 04 XC70?
congratulations and thank you for recording and describing the procedure in such detail. I have the same problem on my volvo xc90, but the mechanic told me that there are 3 different haldex systems for the same model as my volvo. Is that correct and can I see what mine is like without removing it? Thanks in advance
I believe Mike explained with a verbal description where the filter is relative to the pump. Take a peek around yours and see how its layout matches his descriptions.
Is it normal to hear my haldex pump running for a minute or two after I shut the engine down?
Forgot to bleed out the air and drive it warm to bleed out the oil when warm. (just a note) :-) Otherwise nice work!
Amazing video thank you. I've purchased all my volvo spares from FCP Euro and love this content. I've tackled the more difficult jobs, I'm just having trouble getting the flange off. I've tried some gentle and not so gentle persuasion and giving it a good degrease but the thing won't budge. 24mm nut has been removed. Any tips??
Soaking it in some penetrating fluid for a bit should help! If it is still really stuck, a slide hammer may be the way to go.
You could use a hammer drill in a hammer mode.
yes code is DEM-0006 Pump faulty signal
💙
P3 Haldex 4 next, please.
Also, Recommended service interval for Haldex systems?
Hi David, we have it on our queue! The interval should be the same however as this.
How do you tell if your rwd failed due to that pump or the spline on the bevel gear? i'm gonna have to do it myself and cant really be tearing down and replacing the wrong parts.
Get the codes read with vida, most common pump failures are dem-0006 and dem-0007,if you have no codes for the awd system then it will likely be the bevel gear. The only way to defo know is too check.
helo I have a problem with volvo v70 haldex gen 3 rear wheals dont spin when is it in drive now I have one thing on my mind does the central shaft spins when haldex dont work
Yes. The central shaft will spin even if the haldex is out. If your driveshaft is not spinning, you have an angle gear/shaft collar issue.
mine work like that but on road doesnt work , vcds say electronik valve error N373 , Can you help me ?
Unfortunately, it sounds like some further diagnosing will need to be done!
hello, on my xc70 from 2003 with a haldex gen2 during a trail I heard a "clunk" and lost the rear traction. In the diagnostic machine there was an error in the hydraulic pressure, I changed the filter, pump and fluid but it still does not work, any clues
Check the angle gear
@@MrBenji959 or the collar shaft going to the angle gear.
Please explain why the rear wheels do not spin before the servicing.
So the haldex system comprises of an angle gear, delivering power through a driveshaft to a clutch unit. The clutch unit has a pump which generates pressure to engage the rear wheels and delivers power to the rear axles. The pump is bad in this case, which is why the rear wheels weren’t spinning. Pump was not generating pressure to engage the active on demand coupling in the haldex system.
@@jacksonriecken5016 how do you confirm the pump was bad and not the spline coupler on the bevel gear? i dont want to spend uneeded time, money and curses
@@user-pc2qt2pj2r if the spline coupler is bad, the driveshaft going from the front to the back will not spin.
Yah they should have included footage of the propshaft when the vehicle was lifted and spinning the front wheels.
By removing the pump, does that count as a complete drain the Haldex?
Hi Roy, that would be as much as it can be drained without removing the whole assembly from the vehicle.
@FCP Euro I saw a video about using an extraction pump with hose in the fill hole ...
Great videos on the xc90. I'm sure the other vehicles are just as good too. I got 2 xc90's and whoever knows how to do this in my area wants a arm and a leg to do it.
@@fcpeuro Is it a good idea to blow compressed air into the fill hole to blow out as much old oil as possible?
Is that fuel tank cracked?
It was just a shield that has seen better days!
Why not replace the flange Seal D:
They should make a DIY on the angle gear and flange seal replacements
Is it a possibility to remove and service the pump on a 2005 S60R without removing the driveshaft? I can definitely tell it's tight down there but it looks like it can be removed without pulling the shaft.
I was wondering the same thing. The top bolt on the pump looks tight, but could you do it blind? The filter definitely looks doable with patience. the fill plug is right there. Did you get to it yet?
@@gotredeemed not yet. Currently focused on doing a FMIC upgrade from scratch so I've been fabbing mounts and shit. Better paying $300 to do it myself than $1000 for a comparable kit premade where I have to do most of the work still aside from cutting a pipe, bead rolling it and welding on a singular bung
@@gotredeemed 04 S60R owner here - and have done this job before - it is VERY tight - and ultimately, it's easier to remove the flange than not. I've done it both ways, but the extra 10 minutes pulling the flange makes it a lot easier to access. So yes, it can be done, but...
So there was this guy who loved his old, beat-up VW Beetle with a super-low front bumper. He decided to take it on a trip to Silicon Valley to withdraw all his money from the bank. As he was driving, a new XC90 passed him by. Despite the XC90 being newer and faster, the guy was happy and content with his trusty old car.
Thanks for reading my comment despite the fact it hasn’t got much likes.
using a vehicle with a modded exhaust is not nice. in fact pretty lame because on mine at least (07 3.2) there is no coupling of the pipe. there is a big 'ol muffler there. no joint. there is a flange AHEAD of the muffler with very rusty, corroded bolts which are sure to break right off. vid makes this job look pretty easy when in fact, at least on my yr/model, it appears i'll have to fight with it and work around the ex hanging in my way. and don't get me started on the use of a lift.
Please upload video Hindi language thank you so much help
TH-cam should have kept the community generated captions submissions
How do you tell if its the Haldex that has failed and not the transfer case that has failed?
With all 4 wheels in the air, vehicle off, in neutral, if you rotate the driveshaft do the front wheels rotate? One or both - if they rotate, then your angle gear/shaft collar are working - if they don't then it's in there instead of the haldex.
Nice DIY!! Wow, this is a terrible engineering effort from Volvo.
There are a lot of other places to claim that - that haldex unit hasn't been a big issue... my subset of 1 with 270,000 miles on it... original haldex, 3d angle gear and 3rd shaft collar.