A couple weeks ago I took my 2008 Volvo S40 2.4i to the garage (Firestone) for a regular oil and filter change. They told me that my front-left axle was "broken" and leaking fluid. I'm not sure if the issue was only the boot or the entire shaft, but they said the whole thing should be replaced. They quoted me at $280 total for an aftermarket part as opposed to $900-something for the OE part. I said go ahead and do the aftermarket.

As soon as I drove the car off their lot, I got on the highway and experienced vibrations in the steering wheel, gas pedal, and under the seat at around 50-70 mph. The steering would vibrate by shaking or tick-tocking left and right. The issue is very noticeable at these higher speeds, especially 60 mph, and to a lesser extent when driving through town at slow speeds while making turns into driveways, etc.

I took the car back to the garage right away and they claimed the issue was due to my tires being worn down. I pleaded with them that even though the tires weren't the greatest and needed replacement, the vibration issue only existed after they did the axle job. They insisted, so I had all four tires replaced with Conti PureContacts.

Even thought the ride is generally quieter, the new tires didn't fix the vibration issue at all, so I went back. They tried a new alignment. Didn't work. They tried to re-balance the tires. Didn't work. They then finally admitted it was a drivetrain issue and swapped out the rebuilt axle they first installed for a brand new one under warranty (still Chinese-made presumably). Didn't work.

Since I have ZERO confidence in these shmucks, I took the car to another garage and they also feel that it is a drivetrain issue. They suggested that the first garage put counterweights on the axle to bring it back into balance. Do you think I should go back and have them try that? Or should I try to have them reinstall my old "broken" one (if they have it) which caused me no trouble until they replaced it.

I would go to a Volvo dealer but I have a feeling that they would quickly recommend a new OE axle and charge me exorbitantly for it. What do you all think?

 

Always insist on them giving you back the old parts. This is to prevent unscrupulous mechanics from replacing good parts needlessly. Not a guarantee as they can purposely damage a part, but more a warning that you are watching them.

I would suspect, as you, that the new axle is out of balance. IPD sells a new axle for $98.
Volvo Left Front Axle Assembly - P1 C30 C70 S40 V50 FWD Automatic Transmission AUP 124194 AUP7823N, 36000550, 36000441, 7823, 709075092339, 36000183, 36000439, 36000548, 8603119, 8603121, 8603819, 8603821
Rock Auto sells remans for $45 plus core. New for $60.
EMPI/EMPIRE Part # 807819

The shop you are dealing with are parts changers. Keep after them until they make it right.

 

I agree that it is most likely the axle. I've seen more than a handful of customers with cheap aftermarket axles that have problems. Never had an issue installing OEM ones.

 

Depending on your budget situation I'd be tempted to cut my losses never go back there, order an ipd axle or a reasonably priced oem one from tasca motors and get someone else to install it. Or you could tell them to split the cost of an oem replacement and have them install...I would be concerned with letting them touch your vehicle that's my biggest worry.

 

Thanks.. Which part # would I get? There are two listed on the site for the front-left shaft.

CV Components for 2008 Volvo S40

 

Hmm, not sure, give tasca a call and make sure you have your car serial # handy. They will sort you out. BTW - you may want to also pick up the expander ring just in case. Note that you'll have a core charge too which means that they will ding you an extra "core" charge until they receive the old piece back...