I have a 05 XC90 T-6 2.9 AWD with 197k miles and this car keep blowing apart right front axles. At first I thought it was a defective axle, then I thought it was just a poor quality aftermarket axle, so then I tried a different manufacture for the axle, then I replaced every signal motor/transmission mount and yet again the axle is vibrating like crazy.

One of the axles actually flew apart and the actual shaft of the axle came out and flew out from under the car. Only thing left was the inner and outer CV joint cups.

You shift the transmission front R to D while pressing the gas and brake and there is no movement in the engine or the wheel.

What the hell is going on with the POS?

 

Side note: every time I replace the axle its fine for a while, last axle lasted 40 miles before it started to vibrate.

 

So you've never used a Volvo axle?

Is it installed correctly?

 

No i haven't used a Volvo Axle and yes it has been installed correctly.

 

I'd bet it's the axle then

 

I just put the original OEM Volvo axle back in it and drove it about 8-10 miles and the inner CV joint feels like it is on fire. The last aftermarket axle I pulled out built up so much heat in the inner CV Joint that it actually turned the cup part of the CV axle blue.

 

Are you installing the axles yourself or paying someone to do it?

The only way I can imagine the inner CV joint getting that hot is if there were no grease in it.

I'd have to guess you've been unlucky and installed two aftermarket axles both with fatal manufacturing/assembly errors - e.g. no grease in the joint.

 

Yes, I'm installing them myself into a customers car.

I own a automotive repair shop and a ASE Master Certified Technician.

This one has got me stumped. In my 20 years of working on cars I've never seen a axle do this.

It's had a total of 4 aftermarket axles installed into it, needless to say I've gotten pretty quick at replacing the axle by now (less than 10 mins).

 

There's really nothing that can cause it outside of a low quality axle.

I hope you're careful when replacing the axle so you don't damage the seal inside the chain gear, which would allow trans fluid into the chain gear. I've seen many people make that mistake. You should also suck out trans fluid before removing the axle, but it doesn't sound like that's happening.

 

Four blown axles? Wow.

Two could be coincidence but four? Hmmm. Has this vehicle had a front end collision repair?

 

He's a professional, of course he's being careful not to do that.

 

Is that car is AWD?

Is yes, "maybe" the problem can be that is using diferent size tires in the front than in the rear and the AWD is making more force in the front.

Isaac

 

I am running into similar issue with my front passenger Axle.
I have a 2005 T6 AWD also.
Were you able to find a solution as to why the car is destroying and heating the axle?
I am on my second axle.
Your response is much appreciated.

 

Use a factory axle. (I do realize they are $$$$ compared to aftermarket )

 

Thanks for timely response!

Talked to Volvo Parts today, they are also asking for old axles to refurbish and resale!
$775 + Tax for Right (Passenger) side

Will that resolve the issue, as the Passenger front axle is getting hot (compared to the driver side) and starts vibrating after driving 30 miles?
Tech talking about Transfer Casing but I am not buying that suggestion yet. I advised him of the Fluid in the transfer casing but there is no leak or noise coming from Casing.

Please advise.

 

I used a RF aftermarket axle on a t6 xc90 ONCE. The factory part was not available the day I needed one and a customer wanted their car back NOW. A week later she has a complaint, I drive the car - no problem - so she leaves the car (reluctantly). I drive it 20 minutes on the expressway and HOLY CRAP, what's going on with the steering! Why is it shaking? What's falling off? I presume the "brandy new" chinese outer cv joint was getting so hot it was seizing. A new (factory} axle was installed (at no charge/upcharge for factory - so I had negative profit on the job) and the customer was (almost) pleased. Don't remember if I lost that customer over that instance - but probably.

I hope Volvo will accept you old aftermarket axle as a core - I had a left inner factory one stuck in a transmission, so I could destroy the transmission to get the inner cv out or turn the axle and transmission in at the same time. (both were being replaced) Volvo would not give me the core charge for the axle!

And you should listen to TECH - if he works at a dealership, or has dealership experience he has seen more than I.

 

Thank you so much!
I will talk to tech tomorrow.