SB-10043574-1324

Title

Left front axle frost plug, Missing or displaced. XC90 T6 only

Ref No

US7319.1.1 en-GB

Issuer

-

Partner

3 US 7510 Volvo Cars North America

Status

Released
2012Status Date
03-16
2012Issue Date
03-16
VIDA,
VSTG,
Reference
RTJ
16773

Func Group 4661
Func Desc drive shaft
Attachment
File Name
File Size
Attachment TJ 7319.pdf 0.0606 MB
Vehicle Type
Type Eng

Eng
Desc
B6294T

Sales Body Gear Steer Model Year

275

91

CSC

Customer Symptom Codes

Code
K5
DTC

8

2003-2004

Struc Week
Range
0000690-0088951 0-0

Plant Chassis range
21

Description
Front/rear axle/Oil leakage
Diagnostic Trouble Codes

Text

*16-Mar-2013: No technical updates. Administrative changes only.
DESCRIPTION:
When diagnosing an oil leak from the left front axle, a transmission shifting complaint, or a
Diagnostic Trouble Code (DTC) set in the Transmission Control Module (TCM), it is important
to check that the frost plug inside the axle has not fallen from its location. When the frost plug
falls from its location, axle grease can mix with automatic transmission fluid (ATF). See photo
below. Note that it is not always this obvious and there are two ways to check if axle grease and
ATF are mixing.

SERVICE:
To view TJ attachment continue to next page:

Retailer Technical Journal 7319
Left front axle frost plug,
Missing or displaced
XC90 T6 only

Date 09-11-2009
Volvo Cars of North America, LLC
Technical Engineering

Reference: VIDA, VSTG, RTJ 16773

Note! If using a printed copy of this Retailer Technical Journal, first check for the
latest online version.
AFFECTED VEHICLES:
Model
XC90 T6 AWD

Type
275

Engine
91

Model year
2003 – 2005

Chassis range
ALL

DESCRIPTION:
When diagnosing an oil leak from the left front axle, a transmission shifting complaint, or a
Diagnostic Trouble Code (DTC) set in the Transmission Control Module (TCM), it is important
to check that the frost plug inside the axle has not fallen from its location. When the frost plug
falls from its location, axle grease can mix with automatic transmission fluid (ATF). See photo
below. Note that it is not always this obvious and there are two ways to check if axle grease
and ATF are mixing.
Plug is out of position

Copyright ©2009 Volvo Cars of North America, LLC. All rights reserved.

Page 1 of 2

SERVICE:
There are two checks to see if the frost plug has fallen from its location. If the frost plug has
fallen (on earlier manufactured axles) axle grease mixed with ATF will leak from the bolt hole
in the axle for the hub-to-axle attachment bolt. Remove the hub-to-axle attachment bolt and
check for this. See photo below. This only applies to early axles.

On later axles, the axles are not drilled through and axle grease mixed with ATF will not make
its way to the bolt hole in the axle for the hub-to-axle attachment bolt. On later axles, the left
front axle must be removed from the transmission in order to check if axle grease mixed with
ATF is leaking from the inner side of the axle. Since it is not easy to distinguish between
the two versions of axles, both ways must be checked to be sure the frost plug is in
place!
If the frost plug has fallen from its location but the transmission shifting behavior is
unaffected, replace the axle and flush the transmission and the ATF cooling system (radiator,
auxiliary cooler [if applicable*], and cooler lines) with new ATF of the correct specification
according to VIDA. See RTJ 16773 for the specified ATF.**
If the frost plug has fallen from its location and the transmission shifting behavior is not OK,
replace the transmission, the axle, and the complete ATF cooling system (radiator, auxiliary
cooler [if applicable*], and cooler lines) according to VIDA.
Note! When installing the new axle into the transmission, do not force the axle beyond the
snap ring detent as this can damage the transmission and/or the frost plug of the new axle.
This includes not forcing the hub onto the axle when installing the hub/knuckle/strut assembly
onto the axle.
*Note! All 2003-2005 XC90 T6 vehicles have an auxiliary ATF cooler.
**Note! All 2003-2005 XC90 T6 vehicles use DEXRON III-G or III-H. No other ATF should
be used!
WARRANTY CLAIM INFORMATION
LABOR OP
LABOR DESCRIPTION
46630-2
Driveshaft front left Rem-Inst/replace

LABOR TIME
See VSTG

Claims may be submitted under the new car warranty when there is a documented customer complaint using claim type: 01

VOLVO for life,
Volvo Cars of North America, LLC
Technical Engineering
Copyright ©2009 Volvo Cars of North America, LLC. All rights reserved.

Page 2 of 2