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A customer approached us a little while ago about an issue that he had with his 2011 Volvo XC90. The rear differential unit was making noise, only after about 70k miles. He had talked with several other area shops and none of them had the capability to properly rebuild the differential. So the next step he took was to contact a Volvo dealer and talk with there service department to see if the differential could be rebuilt. They informed him that according to Volvo the only option was to replace the whole assembly at a cost of over   $5,000.00  . That was not a cost effective option, so he contacted Us and we talked about the issues and We decided to go ahead with a rebuild


Volvo XC90 rear differential bearing noise and rebuild

First step was to remove that rear Diff from the vehicle, Once that was complete. I had to order some specialty tools to disassemble the Unit. It is worthy to note that this Diff is also used in Land Rovers  and other AWD vehicles. The housing is a Ford Motor Co.  unit.

Volvo XC90 rear differential rebuild

Next step Was to remove the Haldex unit from the front of the case. This is done by removing the 4 bolts on the front.

Volvo XC90 rear Differential rebuild

This shows the differential completely disassembled and waiting on bearings and seals to be delivered .

Volvo XC90 rear differential pinion removal

Here you can see the Pinion gear being pressed out to replace that bad bearings that are common to fail in these units


Volvo XC90 rear differential disassembly

Here is the Pinion Pressed out of the housing and waiting on new OEM bearings


Volvo XC90 rear differential rebuild

OEM Bearings and Races are installed most seals have been installed. New crush sleeve and pinion Nut .


video of rolling torque and final assembly!