I am having a heck of a time try to remove a bad outer tie rod end on my 16 XC90. I have tried heat, some tapping of the bolt and a 3 arm puller to force the bolt downward. Because of the aluminum knuckle I am leery of putting too much pressure with the puller. I have sprayed plenty of PB blaster. I see Volvo has a hydraulic tool to remove but it's $400...

Anyone have any experience with the removal of one of these on their SPA platform XC90?

 

Maybe, try using a pickle fork. Another option you can try is using a ball joint separator or a tie rod separator tool. These tools can help you loosen stubborn tie rod ends without damaging nearby parts.
Some mechanics also recommend using a vibrating tool, like a pneumatic or electric chisel, to shake off corrosion and make removal easier.