milky gear oil - repair procedure ?

[Deepblue22]

Winterizing my 2002 Volvo 5.0GXi-Sx today.

Drained the gear oil and found 1. the drain bolt was super tight, 2. the gear oil seemed to be gray/milky. 3. no metal on the magnet

Looking for procedure to change seals if that would be the diagnosis.

Thanks !

 

[JustJason]

Re: milky gear oil - repair procedure ?

The procedure to find out whats leaking is easy. Get a pump (even a small tire pump) and adapt what you have to along the way to fit your gear lube pump fitting on to it and then pump up the drive to 10-12psi. Then get a spray bottle with water and dish soap and start spraying until you find the bubbles.

 

[Don S]

Re: milky gear oil - repair procedure ?

Drain all the gear lube and water before you do the pressure test.
Also pull the outdrive and check the bellows for water. That is where most of the SX type drives get water from.

Here is a link to the OEM service manual for your outdrive, you're going to need it.

http://www.4shared.com/file/50982625/e2bdb42c/SX_DP-S_Service_Manual.html

 

[Deepblue22]

Re: milky gear oil - repair procedure ?

Thanks for the info that is great. I am having major problems just getting the fill bolts out, seems like they have never been removed or something.

I will let you know what happens with the pressure test once I can get the oil level plug out.

 

[Don S]

Re: milky gear oil - repair procedure ?

Impact screwdriver.

 

[Deepblue22]

Re: milky gear oil - repair procedure ?

So I pressured it up and it is leaking air from the propshaft area. I have not pulled it to check the bellows yet but will deal with this first.

Don - I read through the information in the manual you linked. What kind of a difficulty rating do you think my current task is ? If I start digging into the gears etc and then have to put it all back I am thinking that is a precise operation better left for the volvo dealer ? Or is replacing the seal relatively easy job and I would not have to get into all the gears and shims and stuff in there ?

Volvo dealer is 3hrs from where I live.

 

[joncrisler]

Re: milky gear oil - repair procedure ?

I have not worked on a Volvo outdrive, but doing a complete reseal job on a Merc lower unit would run about $300-450 including parts. An upper would be $200-350. This sort of depends on the labor rates in your area, but this is a good winter-time job.

This sort of thing is well within the capabilties of the home mechanic, but may require some special tools that could set you back $50-200. Again, my experience is with Mercs so I dont know for sure on the tools.

Its a good thing you caught it when you did, because it should only need a reseal. If you needed bearings or gears that greatly increases the cost. Make sure to tell the mechanic about the oil condition and no metal on the drain plug (assuming its magnetic).