A collection of tools used to service an AWD Volvo AOC.

Volvo AOC (Haldex) Tools

**Use this tool to help drive a new input shaft seal (pn:8675238) into a Volvo AOC (Haldex.)**
**Print Recommendations:**
I recommend this be printed from a strong material such as 3DXTech’s CFPA6 gen 3.


Volvo AOC Input Shaft Seal Drive Tool

Volvo AOC Input Shaft Seal Drive Tool.3mf

**Use this tool to remove an EXTREMELY stubborn AOC (Haldex) flange nut.**
When servicing the AOC on Volvo’s equipped with a Haldex-based AWD system, the AOC flange nut (pn: 31259267) must be removed.  These nuts come with red threadlocker installed and are often over-torqued which can make removal difficult.  This tool can be used with a 7.5mm drill bit to create a series of holes in the face of the flange nut to weaken it, hopefully aiding in removal.  This process is sketchy at best and is only reserved for the most stubborn of AOC flange nuts.  Caution should be taken not to drill too deep, through the flange nut and into the AOC flange itself.  Only drill through the nut in order to weaken it.
**Print Recommendations:**
I recommend this be printed from a strong material such as 3DXTech’s CFPA6 gen 3.


Volvo AOC Flange Nut Drilling Guide

Volvo AOC Flange Nut Drilling Guide.3mf

**Use this tool to remove a stubborn AOC (Haldex) flange nut.**
When servicing the AOC on Volvo’s equipped with a Haldex-based AWD system, the AOC flange nut (pn: 31259267) must be removed.  These nuts come with red threadlocker installed and are often over-torqued which can make removal difficult.  This tool clamps a modified Husky 1/2 in. drive 24 mm 6-point deep impact socket onto the flange nut so that the socket does not lift off and round over the nut.  The tool also has flat sides so it can be held in a bench vise if the AOC is removed from the vehicle.  

The face of the socket should be ground flat to remove the chamfer so as to maximize contact with the flange nut.  The Tool is clamped to the AOC flange using up to 6 M8x100mm socket head cap screws.

**Print Recommendations:**
I recommend this be printed from a strong material such as 3DXTech’s CFPA6 gen 3.


Volvo AOC Flange Counterhold

Volvo AOC Flange Counterhold.3mf

**Tighten up your Volvo’s shifter cable bushing with this 3D printable insert.**
For Volvo M66 6-speed manual transmissions found on the beloved 2004-2007 S60R and V70R.
Replaces the factory shifter cable bushing insert to reduce play in the forward/backward motion of the gear selector.
Installs in about an hour.
Recommended to be printed with unfilled Nylon.

**Background:**
If like me, you have set out on a mission to rid your Volvo’s gear shifter of fun-sucking sloppiness, this bushing insert may be the last piece of the puzzle.  When I finally became fed up with the vague, spongy feel of my 2004 S60R’s gear selector, I installed a short-throw shifter and replaced all shifter bushings in the center console.  The gear selector was greatly improved, however, there was still some forward/backward slop in the gear selector.  Upon inspecting the shifter cables at the transmission end, I found that one of the cable ends was isolated from the transmission shifter bracket via a rubber bushing with a plastic insert.  This rubber bushing has voids that are responsible for this forward/backward slop I was experiencing.  
I have reverse engineered the insert and increased its outer diameter slightly to fit more snugly inside the rubber bushing.  The reduced play in this bushing nearly eliminates forward/backward play in the gear lever giving you much needed feedback to ensure you are shifting comfortably and with precision.  

**Print Specifications:**
I recommend this be printed from unfilled Nylon such as Polymaker CoPA.  Smallest layer height possible as it is a very small part.

**Installation:**
This bushing insert replaces the bushing insert on forward/backward shifter cable bushing on the transmission side, in the engine bay, below the air filter box.  There is a metal clip on the bottom of the bushing that retains the shifter cable bushing to a pin on the shifter bracket on the transmission.  With the metal clip pulled out of its retaining position, the shifter cable bushing can be lifted off of the shifter bracket.  The plastic insert on the shifter cable can be pressed out of the surrounding rubber bushing.  The 3D printed bushing can be reinstalled in its place.  It will fit much more snugly than the factory insert.  The 3D printed insert’s bore can then be lubricated before reinstalling onto the pin of the shifter bracket on the transmission.  The retaining pin can be slid back into place to retain the shifter cable bushing onto the pin of the shifter bracket.


Volvo Shifter Cable Bushing for 6-Speed Manual Transmission

Volvo M66 Shift Cable Bushing Insert.3mf

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Volvo AOC (Haldex) Tools

Volvo AOC Input Shaft Seal Drive Tool

Volvo AOC Flange Nut Drilling Guide

Volvo AOC Flange Counterhold

Volvo Shifter Cable Bushing for 6-Speed Manual Transmission