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2013 XC70 P3 - Volvo xc70 2013 - replacement gearbox, knocking - James Girdler

Hi All,

In need of some advice. Recently purchased the above car, before I did the AWD wasn't working, so the old owner and myself decided a 50/50 split on a replacement gearbox would be the best option. After a while to wait due to the wrong gearbox being sent, it was all working well, it drives fine, however, day 2 I've noticed a clunk/knocking when changing down to 2nd gear from 3rd. I also noticed the same noise on the way home from work down from 4th to 3rd. It's very intermittent. Sometimes it doesn't knock going down from 3rd to 2nd, but other times it does. It's a short sharp knock, like a ratio is wrong or a diff issue. The replacement gearbox was 43k and I have no idea what testing the breakers give them but apparently it was fine. It's a rare one , 6 speed manual with 3 sensors. Took forever and a day to find the right one. After much expense I'm really hoping it's not the gearbox. The original is in my workshop with a seized output spline , hence the replacement. Not sure if I should refurbish that if it comes to it - depending on internal damage. Though guessing there is either an issue with the replacement gearbox - hence the reason it was scrapped, or issue with replacing it and causing another problem with the car. Otherwise drives fine, but I guess this knocking will get worse/louder in time. Sounds like popping a joint. I'm speaking to the mechanic who fitted tomorrow. Problem is, it's exhausted him as it caused so much grief, so essentially I'm the only one with the problem here. Owner is paid, mechanic is paid, I'll be the one losing out. 3 mo the warranty on gearbox, but no idea what that covers, I'm sure their ass is covered . Bought the car, 2 days of owning it, the saga continues. Any advice or ideas greatly appreciated

Thanks

2013 XC70 P3 - Volvo xc70 2013 - replacement gearbox, knocking - Adampr

My only thought (in some ignorance of how Volvo AWD systems work) is that the sound may be coming from further 'down' the transmission, such as the transfer box or prop shaft. Presumably, they haven't been used in a while and have just been connected up a new gearbox. The intermittent nature of the problem may be linked to when the AWD is engaging.

2013 XC70 P3 - Volvo xc70 2013 - replacement gearbox, knocking - Adampr

Google tells me the AWD is a Haldex system. They are know to have their quirks and I would suggest that's a good place to start. It may need new fluid or a filter, or may be cream-crackerred.

2013 XC70 P3 - Volvo xc70 2013 - replacement gearbox, knocking - James Girdler

It had new fluid when it was replaced, but I did wonder if the haldex was knackered. It's around £170-200 for a second hand Haldex unit, so might be required, though I would have thought with a failing Haldex there would be warning messages showing up? Speaking to mechanic tomorrow. Will see what he says the next best step is. All gears smooth going UP through the gears, but it's just when going down, from 4th to 3rd and 3rd to 2nd, also did it right at the last moment 2nd to 1st. So only down, I guess when AWD is more likely to engage to compensate for speed change ? Not entirely sure how Haldex systems work.

2013 XC70 P3 - Volvo xc70 2013 - replacement gearbox, knocking - James Girdler

Hi, thanks for the reply. That was my original thought with replacing the gearbox. The previous owner had it since 2019 and maintained it very well, I test drove it a few months back, it went into his mechanic for steering rack replacement and tyres, it's then that the mechanic noticed the AWD wasn't engaging. It may well have been the police that cause the issue when it was X authorities , so over 4 years ago. Or could have been more recent. No one knows as it's never been used for towing. It was just driving in FWD. I did wonder if the Haldex system would have an issue or if the AWD system would be a problem having not been used for so long. It does sound further down the car, but difficult to tell when driving. I guess it might mean replacement prop or transfer box through inactivity? Not familiar with these AWD. Thanks again for the quick reply. I knew my first XC70 wouldn't be without it's issues, but it's literally one thing after a other ??

I guess it would mean replacing each item one at a time to see if it rectifies it? Wondering if driving about like this is going to cause more damage.

2013 XC70 P3 - Volvo xc70 2013 - replacement gearbox, knocking - elekie&a/c doctor
Will it drive with the rear propshaft removed ?
2013 XC70 P3 - Volvo xc70 2013 - replacement gearbox, knocking - James Girdler

That was one of the options.chuck the original gearbox in and remove the propshaft and just have it as a 2WD, but ideally I wanted it for towing. Obviously the cheaper option.