When we start our 2004 XC90 T6 up when it is cold there is a loud rattle sound which seems to be coming from mid car forward, more transmission then engine. It does go away when warm. The sound starts when the car is in gear driving at 30 to 40 Km/hr at 2000 rpms. At higher speeds and at idle the sound goes away.

Any Ideas, the dealer seems to have none???

 

My 2004 T6 had that exact same thing and it turned out to be that the engine mounts were shot which was resulting in the motor moving around which resulted in the drive shaft knocking (or constant clicking until warmed up) Once I had the motor mounts replaced it stopped completely. I was going to replace the drive shaft with one mechanic and then another one found out WHY it was doing that. I am super glad about that because the motor mounts were cheaper than the drive shaft and I would have just wrecked the new one with the same problem. So I would have them check you engine mounts and see how they are.

 

had same issue on my 03,, propeller shaft replaced and all fine now around a 1500.00 canadian repair with labour at volvo