How To Service A Volvo Haldex AWD System (P3 Chassis)

Just like the oil in your engine, the fluid in the Haldex all-wheel drive (AWD) system is critical in keeping the components lubricated. Volvo doesn’t specify any maintenance on the Haldex system but higher mileage cars will benefit from a fluid change. Higher mileage Volvos can also suffer from failed Haldex pumps. All of the fluid will be removed to change the pump and the procedure will be the same during this fluid change.

Volvo models and years applicable:

How much will it cost to service the Haldex AWD system on a Volvo P3?

A Volvo Haldex service kit from FCP Euro will cost around $120. Included in the kit is a bottle of the correct Volvo fluid, a can of brake clean, a new service plug, a Haldex pump seal kit, and a CTA Tools fluid extractor/pump. The fluid extractor/pump is essentially a large syringe used to pump the new Haldex fluid into the system. The syringe can be disassembled for cleaning and can be used to pump or extract any other fluid.

Having the job completed by a reputable shop or dealership will cost around double the cost of our service kit. The shop wouldn’t charge you for the use of the syringe but will charge for the labor. Completing the job on your own will save you money and add to a valuable life skill.

How long will it take to service the Haldex AWD system on a Volvo P3?

While not a physically taxing job, there are several sensitive components being handled. Take extra care when servicing the pump and keep everything clean upon install; any debris can clog the pump. Set aside an hour to complete the job. 

Tools required to service the Haldex AWD system on a Volvo P3:

• Floor Jack 
• Jack Stands
• 10mm Socket
• T10 Torx Bit Socket
• Ratchet set
• Ratchet Extensions
• Flathead Screwdriver
• Flashlight
• Channellocks
• Fluid Syringe
• A small coin
• Pick

Parts required to service the Haldex AWD system on a Volvo P3:

• Volvo Haldex 5 Service Kit

Steps required to service the Haldex AWD system on a Volvo P3:

Step 1: Remove the Haldex pump

Jack the rear of the Volvo up as far as the jack will go and then set the car onto jack stands. At the back of the transmission sit the Haldex system. Locate the electrical connection from the pump and disconnect it. 

Next, use a 10mm socket and remove the two bolts mounting the pump to the differential. Wiggle the pump side to side, and pull it out. Have a catch pan under the pump to catch the fluid that will come out. 

Step 2: Service the Haldex pump 3:34

Place the pump onto a clean work surface and have the new seals ready. Then, take a T10 bit socket and remove the two screws mounting the screen to the pump. There may be a decent amount of black gunk inside the filter that will need to be cleaned out. Brake clean and a rag will remove the residue. 

Next, use a pick to remove the two o-rings from the pump. Use brake clean and a rag to clean the entire surface of the pump that sits inside of the differential housing. Install the two new o-rings and the filter once the pump has been cleaned. 

Use the brake clean to clear out any gunk that may reside in the differential housing where the pump sits. Then, dip your finger or a rag into the new Haldex fluid and wipe some onto the new o-rings to lubricate them for the pump reinstallation. Resecure the pump to the housing with the two 10mm bolts, and then plug the pump back into the pump controller. 

Step 3: Refill the Haldex fluid

Just behind the pump is the plastic fill plug. There is a slit in the center of the plug, about the thickness of a dime. A flathead screwdriver would work but there isn’t enough space without removing the exhaust. Use a dime or similarly sized coin to open and remove the fill plug. 

Fill the syringe with the new Haldex fluid and pump it into the fill hole. Continue to fill the system until the fluid starts to leak out slowly. 

Reinsert the fill plug and tighten with the coin. Clean off any fluid that ran out of the diff with the brake clean. 

Then, set the car onto the ground and go for a test drive. This will cycle the fluid through the system. Raise the car back up after the test drive and check the fluid level, adding as needed. 

That concludes the service on the Haldex AWD system. If you’re interested in more DIYs for your Volvo, you can visit volvo.fcpeuro.com and subscribe to our YouTube channel.

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Written by :

Christian Schaefer

Car and motorsports-obsessed writer/editor for FCP Euro's DIY Blog. Constantly dreaming of competing behind the wheel or searching for another project. Owner of a turbo Subaru Forester and a ratty Porsche 914, neither of which are running.