Hello all new here to this forum with my first 2009 volvo xc90 4.4l v8 and absolutely love the vehicle. I do all mechanical work myself with over 15 years of mechanical experience but this is my first volvo and want to get this right and had a couple questions for those with knowledge. My angle gear is leaking from between where it bolts up to the transmission and I plan on changing the seal. I already know how to remove the angle gear I just drop the entire engine and transmission together since its pretty simple vs trying to squeeze things out and unbolt with minimal space. My question is after the gear is unbolted off the transmisison what seals should I look for and is there anything special regarding changing it/them. Or for anyone who has done this, is it pretty simple and straight forward?

 

OK - if you want to drop the engine/trans/subframe - go for it!\

The angle drive comes off easily without that - but if your angle drive is leaking - is it because someone overfilled it? Have you verified it is actually low on fluid? The fluid level in the angle drive is below the bottom of the oil seals - so - Are you sure it's your angle drive leaking? - Does the fluid leak smell like HP oil (stinky diff HP oil?)

I have been there and done that - take stuff apart that I really did not need to. But it can be fun - if you don't need to drive the car the next day or anytime soon!

 

Thank you for replying, I replaced the engine with a used one and afterward it kept leaking from that area near where the passenger axle goes into the transmission but more on the side where the angle gear bolts up directly underneath it. I removed the angle gear when i was doing all of this to inspect and clean and upon reassembly noticed it was leaking not too bad but enough to notice a spot overnight and you can visibly see it dripping a bit from that area nothing too major. It looks and smells like regular transmission fluid and even has that red color to it (I put new fluid in transmission as well). However, i did initially overfill the transmission fluid greatly i think Since I couldn't find any accurate information on fill levels and procedures (my first Volvo) I called dealer initially and they told me 12qt on a complete fill including torque converter but when i got to about 9qt the transmission overfilled and came out the drain plug so maybe this could be the cause of the leak i am seeing? I have since tried to adjust the level to proper spec via the level plug on the bottom. I used AutoZone fluid for the trans which i think I'm going to switch over to Volvo genuine fluid since i am now getting hard shifting into reverse and slight shift judder. Hopefully this time I can get the proper levels after a complete flush. I have taken this engine down and can do it now in about 3 hours which makes everything else so easy to work on which is why i prefer this route to get a better look at things and easy angles to clean and replace as necessary.

 

The transmission fill volume from completely dry is 6.7 liters. So if you put in 9!!!! - it is overfilled. The type of fluid used is also critical - it might take 12 quarts flushing the system to get the pep boys fluid out.
Search for "Gibbons Method" for flushing method ideas. Hopefully a seal was not pushed out/damaged.

 

Oh wow so its basically 7qt and that is completely dry meaning the torque converter was empty as well? I ran the vehicle a bit after overfilling the crap out of it but never drove just shifted through the gears before learning that the drain plug underneath is 2 in 1 design lol I Initially accidentally only pulled the level plug and let it drip out there thinking that was the drain and then continued to pour 9qt of fluid into the trans before it overflowed out of the fill hole below the intake box. I since then tried to let it run on the lift and pulled the level plug after until it barely dripped and assumed it was correct level after that since temperature was at operating temp and it wasn't pouring out the level plug like crazy and just barely streaming out. I'm definitely going to redo it with volvo fluid and make sure its all flushed out properly. Wouldn't I be safe to just fill with 7qt after a flush and completely empty? Also does the passenger axle have a seal that is inside the transmission? I took mine out when I had the engine out but couldn't see any seals there at all, nearly done fixing all the other things on this car but so far it runs and drives strong the trans fluid leak is very slight at the moment and only showing a small spot over night sitting. Thank you for answering my questions and helping me, are you a volvo mechanic or have been in the past?

 

You can never get the trans completely empty. A few quarts stay in the torque converter and there's no way to drain it. You can only mix in good fluid, and drain and fill a few times to mix in as much good fluid as possible or use a flush procedure. Don't remember on that trans - but a drain and fill on the 01- AW50/51 is only 3.5 quarts. That trans holds 7.1 liters.