Differential Electronic Module (DEM), Pump and Filter Removal Procedure for Volvo Haldex AWD

Welcome to XeMODeX. Today we're featuring a step-by-step tutorial on how to safely remove your Differential Electronic Module (DEM) from your Volvo.
This DEM removal tutorial applies to the following models:
All Volvo Models 2003 - 2015
For more tech tips, and to see a full list of our products and services, please visit www.xemodex.com. For repairs and purchases email us at [e-mail]
#DEM #Volvo

[@vitalyp.90]

Great video! It shows me how to service the diff, that's very valuable, but the information about each piece, and the tech tips on each component, the filter + fluid, the blown fuse, the pump, etc. IS PRICELESS!!! Thank you very much! This information will save us a lot of time and money! Can't pay enough for someone to teach you this!

[@XemodexInc]

We sincerely appreciate the positive feedback, Vitaly. Thanks for watching!

[@arivaisanen4561]

You need to do more these kind of videos! Very professional and educational work! Thanks a lot! I will give the link to Volvo forum guys in Finland.

[@XemodexInc]

Glad you liked it, Ari! Thanks for watching.

[@johnmcisaac7799]

Thanks very much for this info ,one of the best video. Having the unit removed is the perfect way to show exactly what the procedure is to to repair or maintain the volvo AWD..

[@XemodexInc]

You're welcome! Happy to help:)

[@marcojaen5626]

The video was very helpful to understand all the possible mishaps in the replacement of the DEM. Thank you guys!!!

[@XemodexInc]

You're welcome, Marco!

[@dale797]

Very well presented! We are working on my son's 2004 Volvo

[@XemodexInc]

Glad it was helpful!

[@rionsumisu]

To get the flange off at 10:40ish i found a 3" two jaw gear puller perfect. Didn't require much effort but would have been challenging to tap it off with a hammer while still on the car.

[@JJRamirezP]

Great video, very informative. I do have a Volvo xc90, 2.5T AWD 2007 with the same problem, the rear wheels are not engaging. This will help me a lot. thanks

[@XemodexInc]

Hi Juan. Glad we could help! If you have any other questions just let us know.

[@andrewharris2772]

Spot on vid, had a low pressure fault, fully serviced and did exactly what you did all working now thank you, the oil level was low after removing the pump, can the oil leak in the the diff at all as I had no external leaks.

[@materajic7677]

Dear @Andrew Harris, can you please tell me how did you diagnose the fault? Did you had to put new pump in?

[@XemodexInc]

Happy to help!

[@lev1g]

Is there a way to clean the pump without taking it out or the fresh oil will do this?

[@zx12rcezarjusz]

Dzięki za fajny i pomocny materiał.

[@thewalkingmiracle8410]

Thanks for working on my (DEM) highly recommend

[@XemodexInc]

Thanks for your endorsement! We appreciate it!

[@adammurday17]

Will this leak more if we are doing this while on the car? How do you suggest doing this while on the vehicle?

[@BenHur872]

Thank you for this video. Very clear and helpful.

[@turbogarcia3602]

So that yellow bolt is for the actual rear diff fluid

[@juanortiz3523]

Hi, what kind of oil the dem use? Brake oul? How do i check the oil levels ?

[@alinbmw9744]

Hello, please help me and I know that I don't know where to go to repair the car. I bought a Volvo xc90 in 2004 and it doesn't engage the back, the gimbal doesn't turn, I picked it up on the elevator or elevator, the mechanic put it on I put the speed on the elevator high and it doesn't spin the wheels on the back with the cardan the test gave me that there are two fault modules one from the group and one from the gearbox in front tips that's the problem of not engaging the back and not turning the gimbal thank you

[@julielong1348]

all done problem solved thanks x

[@XemodexInc]

You're welcome!

[@rionsumisu]

Great video, thanks! Should be very useful. No attempt to remove the old fluid though? Sticking a bit of tubing in the filler hole and sucking it out with a syringe for example? Any idea how much fluid is in there?

[@danielrybarczyk6954]

Thank You for that video!

[@XemodexInc]

You're welcome, Daniel!

[@briandoerner2620]

I just got an 2006 XC 90 ..I've driven it 1000'? and I've removed the alternator for rebuilt..why are there so many videos on this repair...what goes wrong with them?

[@rolandcyr5747]

Hi and thanks for the video. This unit looks very similar to the one on my 2005 Mercury Montego AWD Premier. Is this correct? This has been a very problematic unit for me. My car has been thru two of them. I asked the Ford dealership if the AWD system could be disabled and was told they could disconnect the AWD control module and the car would safely be just FWD. Is this a simple DIY procedure or should I take the vehicle to the dealership. Thank you for your input.

[@XemodexInc]

Hi Roland. We suggest taking your vehicle to the dealership for this procedure. Alternatively, we do offer a repair service for your 2005 Ford Mercury Montego DEM. You can learn more about our repair service on our website here: xemodex.com/us/product/differential-electronic-module-for-ford-fo-1040-7f9z-4c016-10-20/

[@BuiltForSpeed]

So the filter will be kn 2014 volvo s60 rdesign awd as well same filter?

[@HOARedneck]

My AWD isn't working on my 2004 XC90 2.5t AWD and I can move my driveshaft with all 4 wheels on the ground and in park but doesn't make any noise from the bevel gear during driving. Do you think it's something in the diff or the sleeve connecting the trans and bevel gear? I also already checked the AWD fuse in the back and it was good.

[@XemodexInc]

We'd need the tech to advise more. If you haven't already fixed this, then fill out this form: xemodex.com/us/technical-question-form/

[@atleast1969]

Fantastic video ...my question is size of rings in both sensor or part kit number please gen 3 land Rover 2008 thanks a lot of you can pass the information

[@XemodexInc]

Hi Alberto. You can contact our Tech Support department if you still require assistance with your troubleshooting. Simply fill out a "Technical Questions" contact form on our website. We're happy to help.

[@osvaldomateo5853]

Were is the fuse that blow located

[@germplus]

My haldex is leaking from the front flange. I am guessing its a broken seal. Is it hard to take out?

[@civicaerodeck14]

Hello! Id like to know how i remove the haldex system from the differential ON the car and where i can fill up the differential oil, because the haldex and the diff use different types of oil, as far as i know.

[@dapymp17]

If replacing a blown motor does the drive shaft need to be removed? I'll be doing the job in my driveway

[@XemodexInc]

Yes the motor and assembly must be removed, but this is an extensive job. You will need to raise the car high enough (on a vehicle hoist) to remove the motor and assembly from underneath the car. We do not recommend doing this procedure on your driveway.

[@OliCM3]

Did you manage to get it done in the end? Any tips or comments you can pass on to me before I tackle it..? Cheers.

[@maveric0738]

Great video. Looks like Haldex Generation 2? Do you happen to have any builds on Haldex Generation 1?

[@nickoglock]

great video thank you

[@ericpoulin5019]

i have a problem with my passat 2006 4motion i have a code haldex pump default ?

[@XemodexInc]

Hi Eric. Please contact us toll-free at 1-888-712-2525 and ask to speak to our tech support. They will help determine the issue. Thank you.

[@aarong5727]

Will this unit when it goes bad cause an ABS light to come on or if you got one from a used car and put it on a different one will it throw a Traction control light ABS light to be displayed on the dash

[@XemodexInc]

Hi Aaron. You can contact our Tech Support department if you still require assistance with your troubleshooting. Simply fill out a "Technical Questions" form on our website. We're happy to help.

[@Rainy_Cloud]

do you have to drop the whole sub-frame to remove differential>

[@jonjackson1901]

If the DEM goes bad or contacts get wet, can your car go into limp mode and have instrument cluster, a/c problems?

[@XemodexInc]

Hi Jon. You can contact our Tech Support department if you still require assistance with your troubleshooting. Simply fill out a "Technical Questions" form on our website. We're happy to help.

[@rholennford4087]

Escuse me sir, I have a 2004 volvo xc90 t6 Sport 2.9L turbo, and it has a bunch of numbers on the white label on the side of the DEM haldex unit. The first line says: SIEMENS VOLVO, the 2nd line says: 5WP22201 05 102160 , the 3rd line reads: HAP511 1515 28.07.03/2 , Which numbers do I need to pay attention to if I wanted to by a replacement unit where I wouldn't have to worry about the new unit not being compatible or having to program it to my vehicle?

[@XemodexInc]

Hi Rholenn, Unfortunately we do not provide Pre-Programmed units for the DEM so we cannot provide you with a compatible unit out of the box. However, we do offer a Repair service where you can send us your existing DEM unit to get rebuilt. You do not need to worry about part numbers as we will repair your existing unit and send it back to you fully remanufactured. We also recommend that you test your Haldex Pump & Filter as these are susceptible to failure. We do offer a Repair package for the DEM, Pump & Filter. You can visit our website for more information: xemodex.com/us/product-tag/available-services-for-dem/

[@csebastian71]

I’ve been searching for a source of a sound I’m getting. When I decelerate from 60 to 40mph I get a humming sound. I checked the drive shaft and feels tight. Had the XC90 up and all wheels spin. Do you think the DEM can be failing?

[@XemodexInc]

Hi Sebastian. Please contact us to speak to our tech so we can help you diagnose your vehicle over the phone. You may contact us toll-free at 1-888-712-2525 or visit xemodex.com.

[@jennadollface]

i have a 2005 audi A3 3.2 quattro ive took of the haldex controller cleaned look fine inside all back on fitted and had NEW clutch pump fitted but still no Quattro ? does the new clutch pump have to be programmed into car or anything . hope you can help. otherwise it must be a bad wire somewhere

[@XemodexInc]

Hi Janna. Please contact us directly to speak to our tech specialist regarding your vehicle diagnosis. Call us toll-free at 1-888-712-2525 (US & Canada) or email us info(at)xemodex.com. Thank you.

[@volvoripr9980]

Hi guys , I just bought an xc90 2007 v8 , awd isnt working , I would like to fix this before winter , I was told it was the pump, is there a way to diagnose this , I get a messages on the dash after 3 o 4 seconds when i start the car, please help , I am in Ontario

[@XemodexInc]

Hello! Please contact us directly to speak to our tech specialist regarding your vehicle diagnosis. Call us toll-free at 1-888-712-2525 (US & Canada) or email us info(at)xemodex.com. Thank you.

[@alfredomariscal6869]

Hi I have a ford freestyle 2005 and the code from the scanner is p0961 say that is the solenoid A could it be that is just the solenoid in the module . Thanks

[@XemodexInc]

Hi Alfredo. Please read the following response from our tech: For the ford freestyle DTC-P0961 yes it is possible it’s just a solenoid. Code Description: The pressure control (PC) solenoid valve is an electronic device that regulates transmission line pressure based on the current flow through its coil winding. The magnetic field produced by the coil moves the solenoid's internal valve which varies pressure to the pressure regulator valve. The transmission control module (TCM) controls the PC solenoid valve by applying a varying amount of amperage to the solenoid. The applied amperage can vary from 0.1-1.1 amps. Low amperage, 0.1 amp, indicates high line pressure. High amperage, 1.1 amps, indicates low line pressure. The duty cycle of the PC solenoid valve is expressed as a percentage of energized ON time. Zero percent indicates zero ON time, non-energized, or no current flow. Approximately 60 percent at idle indicates maximum ON time, energized, or high current flow. The TCM determines the appropriate line pressure for a given load by comparing the throttle position sensor voltage, the engine speed and other inputs. When the TCM detects a continuous open or short to ground in the PC solenoid valve circuit, then DTC P0961 sets.

[@austinalford51]

You guys have a repair service for a 2003 xc70 Dem? Website? Price? I heard it needs to be programmed exactly the same if you get a new one

[@XemodexInc]

Hi Austin. You can check out our prices on our website xemodex.com or speak to our Customer Service toll-free at 1-888-712-2525 (US & Canada).

[@julielong1348]

hi i have ford kuga 2011 haldex awd pump failure .the pump is same as your volvo would it be worth us giving it a service as its only done 24.000 miles ford just say buy new unit but hubby says can he service it and would it be worth taking a chance that its just gunged up ?

[@XemodexInc]

Hi Julie. I spoke to our tech and he said if it's just the pump then to replace the pump, filter and fluid. If the Haldex unit is acting up, then test the pump first before sending your unit in for repair. You can check our website in the "technical resources" section for our pump test flow chart. We recommend replacing the pump, filter and fluid when you replace/repair your Haldex AWD unit.

[@johnmahoney6663]

Can you change the pump filter with out removing the large flange.

[@XemodexInc]

Hi John. In the video, our tech mentions that the clearance between the pump and the flange is minimal. You must remove the flange first to gain access to the pump.

[@johnmahoney6663]

THX

[@alexandercabral1396]

can I buy a new one preprogrammed already for a 04 s60r

[@XemodexInc]

Hi Alexander. No, but we do offer a DEM repair and return service. Please call us toll-free (US & Canada) at 1-888-712-2525 or email [e-mail] to speak to our sales department. Thank you!

[@alexandercabral1396]

thank you

[@vicenteleal3455]

hi there is there a place where i can send my (DEM) to have it check before i get me a new one. thanks

[@XemodexInc]

Hi Vicente, to place an inspection order, please contact us toll-free at 1-888-712-2525 (US & Canada) or email us [e-mail]. Thank you.

[@vendavalm3e30]

Have a question. when this DEM fail the awd doesn´t work anymore?

[@XemodexInc]

+Cocco Shop Hello! Yes, you are correct. When your DEM fails your AWD will not function.

[@niklasnilsson9392]

when removing the flange is it aoc fluid that's coming out ?

[@XemodexInc]

Hi Niklas. I spoke to our tech and he said that it is gear oil/AOC fluid. Only a small amount should come out. He said you must drain out and change the fluid.

[@pbierre]

When you remove the filter cap and filter, that's when the AOC fluid spills out...be ready with a catcher pan. This completes the drain process.

[@pbierre]

Or, it will drain AOC oil when the pump is removed, whichever you remove first.

[@henrykyoustupid]

Hello, is this Haldex assembly shown in this video generation 2?

[@XemodexInc]

Hi Henry, For this demonstration, we are using a DEM from a 2003 S60. However, we can rebuild your unit if it falls under the following years: - 2003-2010 S60 AWD, XC70, XC90 AWD, V70 - 2005-2011 S40, V50 - 2004-2013 S80 (from chasis 335000) - 2010-2013 XC60

[@maveric0738]

Henry Koivisto by the looks of the Haldex control module it does look like a 2nd Generation Haldex system.

[@julielong1348]

can i use volvo transmition fluid ?

[@XemodexInc]

Hi Julie. No, you must use the specific AOC fluid. You can buy it from any Volvo dealer.

[@sansin3732]

Dem 0008 what does this mean ? Is it bad dem ?

[@XemodexInc]

Hi San Sin. We would need more information about your vehicle to determine your issue. Please contact us toll-free at 1-888-712-2525 (US & Canada) or email us [e-mail]. Thank you.

[@xAustinKentx]

Is this more common issue than just the Haldex pump going bad?

[@XemodexInc]

+Austin Kent Hi Austin. We always recommend that our customers should replace the AOC feed pump, filter and oil prior to installing a remanufactured DEM. A clogged AOC filter will over-current the pump that will short internally, subsequently destroying the DEM.

[@xAustinKentx]

+XeMODeX Inc So i just acquired an 05 xc70 that has a bad pump, i'd rather not have to replace the DEM if i don't have to.. is it possible for the pump to go out without taking out the DEM?

[@XemodexInc]

+Austin Kent As long as you can communicate with the DEM then it should be salvageable. First replace and then test the pump for operation. In some extreme cases, the firmware for the DEM may become corrupted and produce a code that cannot be erased. Our tech recommends that you first replace the pump. We have a DEM diagnostic flow chart on our website that you may find helpful: xemodex.com/us/diagnostic-flow-charts/

[@6142bucky]

Hey need advice! 06 xc90 2.5. All of a sudden AWD doesn't work, no grinding, no leaks, worked last winter. When I crawl under car and its in park, the driveshaft spins freely by hand. No codes besides occasional anti skid service required. Could this be the culprit? What could I do to diagnose this ??

[@XemodexInc]

Hello! Please send an email to [e-mail]. Our tech support will help diagnose your issue and answer any questions regarding our products. Thank you.