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"Real" AWD Upgrade - Improved Power Split - Gen 3 Haldex

149K views 574 replies 90 participants last post by  Will Robinson 
#1 · (Edited)
We have successfully swapped a 3rd generation Haldex controller into our V50 and completely transformed how it drives. Launching off the line is insane with power going to the rear wheels immediately and the car now behaves like a true AWD vehicle.

While it's still no Evo or STI, this makes the V50 feel very similar to the Focus RS and it is rather easy to kick out the back end and hold a 4 wheel drift.

There is most definitely an improved front/rear power split. You can actually feel the car pushing you like a RWD, rather than predominantly pulling you like a FWD.
Aside from how the car drives, does anyone know of a cheap or free way to determine the new power split? I'm not looking to spend the money to put this car on a dyno.

The stock gen2 Haldex on our cars is a reactive system with a 70/30 power split.
The gen3 Haldex on the V8 XC90 (aka "Instant Traction") is a proactive system with a 60/40 power split, so the rear wheels are ready to go almost immediately like a real AWD vehicle.

All first generation V8 XC90s and some 3.2L XC90s use the gen3 Haldex controller.
Confirmed Haldex part numbers are: 5Wp33504-01, 5Wp22228-02, 5Wp33504-03, or 5Wp22228-04
Volvo part number is: 36001160

You will need to swap the DEM (differential electronic module), solenoid, and pressure sensor. It takes about 5 minutes and only 2 screws. It's a plug and play upgrade with no software required.



Important Notes:

Just because the back end can kick out so effortlessly does not make this a drift mode like the new RS. Considering the 3 piece drive shaft and tiny rear axles, I would highly discourage attempting to build a drift mode for this car with stock parts.

While this swap is successfully working, with no warning lights or errors, on a 2009 with DSTC and on my 2006 with no traction control. We cannot yet confirm this will flawlessly work on all P1 Volvos.

The real testing begins now, as we determine how this effects the fuel economy and how the rear differential holds up with the added power.

As a full disclaimer, the handling characteristics of the car will be transformed from an easy driving AWD Volvo to a rather insane AWD system. While the car is a lot more fun to drive and actually feels like a sports car, you will have to completely relearn how to drive the car. Throttle control is key, as simply mashing the gas pedal can easily make the back wheels spin.

@MooseTech gets full credit for finding this discovery in the process of successfully building the worlds first AWD C30. More details about that here: https://forums.swedespeed.com/showt...legal-and-consumer-owned-C30-AWD-in-the-world

Update: I think we have ultimately concluded that three results can come from this mod.

1. It works for instant power to be delivered to the rear wheels, making these cars behave more like an all-time AWD when you're in the twisties. My V50 is still showing the improvement after 1 year and 25k miles.
2. It works for a few drive cycles and then the car disables awd until the original module is replaced.
3. It doesn't work at all.

There does not appear to be any indication on why it will or will not work depending on model, year, options, etc. The only way to find out if it works for you is to test it yourself.
 
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#470 ·
Update:

Still working good and no problems. No error with or without DSTC. Works in all modes.

Driving wise, i cant say it transformed the car but some corners it hauls ass trough the corner without understeer. Backend will kick out sometimes and without DSTC on it still kicks in. havent driven that much with the race mode mod so no opinion yet. Hardly any rain but yesterday in a sharp corner after the traffic light with a damp road it still had massive understeer. But hey its not a RWD car, same corner i could do a nice drift with my MX-5, no luck yet with the V50

I still need to hookup VIDA to see what kind of data of the haldex controller i can get out of it to see how it performs now
 
#471 ·
Just had some adjustable rear camber arms installed on Mrs T’s 2005 V50 T5 AWD GT. 10 minutes away “Anti Skid Service Required” DTC pops up. Got it home...used my iCarSoft i906 to clear the code. Drove 10 minutes - ASSR Code pops up again. Drove it home. Parked it overnight - started up the next morning - no ASSR code for 5 miles...then popped up again. Had iCarSoft i906 connected so cleared the code and took it back to Indy who did the camber arm work.

Not able to diagnose/fix the ASSR Code further, so took it in to the nearest Volvo Dealer. Service tech sez my DEM is bad - repair estimate >$2,000.00.

Resurrecting this thread as I’m hoping that replacing my bad P1 Haldex2 DEM with a used Haldex3 DEM will be a far less expensive repair - with the added benefit of a ‘better’ front/rear traction distribution.

What say you - fellow swedespeeders?
 
#472 ·
You get camber arms installed and minutes later your DEM goes bad? Possible, but very unlikely.
Check that the ABS sensors are properly connected and make sure there's not any damage to the sensors or wheel bearing themselves. Maybe they got unplugged or hit with a wrench during the install. All four wheel speed sensors need to be properly working for traction control to function.

Also, don't drive with iCarSoft connect to the OBDII port. I've had this trip a false DSTC error too.

You can unplug your DEM and you're not going to an Anti Skid Service Required message. So I think something else is up.
 
#474 ·
You get camber arms installed and minutes later your DEM goes bad? Possible, but very unlikely.
Check that the ABS sensors are properly connected and make sure there's not any damage to the sensors or wheel bearing themselves. Maybe they got unplugged or hit with a wrench during the install. All four wheel speed sensors need to be properly working for traction control to function.

Also, don't drive with iCarSoft connect to the OBDII port. I've had this trip a false DSTC error too.

You can unplug your DEM and you're not going to an Anti Skid Service Required message. So I think something else is up.
Thanks - my initial reaction as well.

I'll call the Volvo Dealer that diagnosed the "bad" DEM and ask for the Tech's notes on each wheel's ABS sensor data. I was charged $195.00 plus tax for this diagnosis - if their diagnosis wasn't correct or missed an obvious fault (broken ABS sensor or loose connection), then I'll call em out. I really, REALLY hate "replace parts at random til it's fixed" diagnosis...especially at $2,000 per.

Thanks also for the "unplug your iCarSoft Code Reader tip" - now disconnected. I might disconnect the DEM until resolved cuz the dash warning is SO annoying!
 
#473 ·
Ridiculous. They knocked off a wheel sensor. Don't blame them those parts get fragile. But you need a new one.
 
#475 · (Edited)
Yeah - see above response to MyName. I'll put her up on ramps and look around to see if anything obvious is loose or busted. I asked shop that did the Adjustable Camber Arm Install and Front Strut Mount mod to check/clean Wheel Sensor connections. They're not a Volvo specialist however. Volvo Dealer (on the other hand) SHOULD have checked Wheel Sensors and connections during their diagnosis.

If one of the Sensors was damaged..or connection compromised during install - Camber shop said they'd make amends. Would be nice to know which sensor cuz I'd hate to replace em all if only one is bad.

I explained to Volvo Dealer that I had just had some work done on front and rear suspension when I dropped it off.

Comment in Tech notes say "DEM Wiring Harness crimped by Camber Arm" - I asked if this led to DEM failure - Dealer response was "probably not - but you should replace this $100.00 harness anyway"

I brought it back to Camber installer to correct DEM wiring harness placement. They inspected the wiring harness' plastic shielding and saw/found no damage to the harness wiring. They also zip-tied the harness out of the new adjustable camber arm's way.
 
#476 ·
If you disconnect the DEM the warning will always be there. You can diagnose the wheel sensors with a pro tool or VIDA - basically, drive straight and slow and read each wheel speed.

If not available, then closely inspect each rear wheel. The sensor is a little nub at 12 o'clock above each axle, with a single wire leading to it. Inside the hub, there's a star-shaped ring, the points whizz past the sensor and send pulses. Sometimes, those teeth fall off, or the whole ring gets mashed.

Maybe it's just a broken wire or pulled connector.
 
#478 ·
Wheel sensor right rear 2005 AWD

Note how close it, and the connection cable, is to the upper control arm outboard end.
 

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#479 · (Edited)
“I should clarify. A bad DEM should not be giving you an Anti Skid Service Required message. What I mean is that you can unplug your DEM and you still wouldn't see this message, so it is unlikely the DEM is at fault for your warning.

You'll still have the Anti Skid Service Message until you address the problem that is causing that fault.

All that being said, I don't think the DEM gives any sort of fault message on the dash. People who have done the upgrade in this thread completely lack communication with the DEM afterwards, but there is no fault. It's also how many people drive around in FWD without ever knowing there's a problem with the DEM. So it could be possible that you also have a DEM problem which the dealer diagnosed. Easiest way to check for functioning AWD with VIDA is to pull the handbrake one click and take a corner quickly, then do the same with the handbrake off and see how it compares; the handbrake disables rear wheel power.

Thanks MyName. I don’t have access to VIDA - so can’t test AWD using the method you describe. Given your analysis above - agree that DEM ‘might’ be bad (iCarSoft i906 sez ‘No Communication’ with Module). More likely that Adjustable Camber Arm/Front Strut Tower mod installer bumped or damaged a wheel sensor, consequently leading to the Anti Skid Service Required dash message.”


My plan is to call the Volvo Dealer Service Advisor tomorrow and ask for Technician’s notes/diagnostics which led to ‘bad’ DEM and replacement recommendation. If tech didn’t test/check wheel sensors before determining DEM was bad - then tech didn’t read notes about why my V50 was being brought in in the first place.

There has to be a way to test Wheel Sensors, right? tmtalpey suggests a method in an earlier reply. I gotta believe that a Certified Volvo Technician would have a way to to test wheel sensor operation and connectivity to the DEM. If Volvo Tech didn’t test Wheel Sensors - then why did I pay over $200 for ‘fault diagnosis’ which didn’t address the problem (Anti Skid Service Required) I came in with?
 
#480 · (Edited)
“If you disconnect the DEM the warning will always be there. You can diagnose the wheel sensors with a pro tool or VIDA - basically, drive straight and slow and read each wheel speed.

If not available, then closely inspect each rear wheel. The sensor is a little nub at 12 o'clock above each axle, with a single wire leading to it. Inside the hub, there's a star-shaped ring, the points whizz past the sensor and send pulses. Sometimes, those teeth fall off, or the whole ring gets mashed.

Maybe it's just a broken wire or pulled connector.”



Thanks tm. I put the V50 on ramps last night and fumbled around each wheel to see if anything was obviously loose or broken around the wheel sensor(s). Nothing obvious. Then again - these sensors are in pretty awkward locations, so I probably missed something.

As I mentioned in my response to MyName - I’ll call the Volvo Service Advisor and ask some pointed questions about their diagnosis of a bad DEM. I suppose I should have started a new thread topic about my problem...but it’s so much more fun to get responses from “The Collective” on this thread.
 
#481 ·
I put the V50 on ramps last night and fumbled around each wheel to...
You really need to pull the rear wheels. Check out my photo - the sensor is completely behind the wheel and only visible from above. Also follow the wire, which snakes around the back of the trailing arm.

Don't waste your time asking the dealer why they think the DEM is bad. The DEM didn't die as part of the control arm work. It's a wire, or a sensor.

They charged $200 because that's what they do just to assign a guy, put the car on the lift, and plug into the Volvo Borg. Getting a good diagnosis at this dealer costs extra I guess.
 
#482 · (Edited)
"Real" AWD Upgrade - Improved Power Split - Gen 3 Haldex

Alright guys, just did the 33504-01 off of a 2007 XC90 3.2. I immediately threw an anti-skin service warning light. However, me and my friend both drove the car and felt it "pushing" through corners much like a Golf R. I've seen some people say anti-skid means it's not working but some people have said it does work. I'm having a little trouble condensing this thread because it's a lot of debate and hundreds of posts. So,

- I need to put it on a lift to verify it's working completely but it feels like it is.

-Can I expect this mod to shorten the life of/obliterate my angle gear? Especially when I add a Hilton Stage 1.

Anyone got any long term updates on this? I notice that there were some mentions of extreme tire wear. Has anyone had to replace tires with extreme irregularity?

EDIT: VIDA has informed me that the brake module and the car itself are unable to communicate with the DEM, which means that the brake module issue is causing my fault.

Sent from my iPhone using Tapatalk
 
#483 ·
EDIT: VIDA has informed me that the brake module and the car itself are unable to communicate with the DEM, which means that the brake module issue is causing my fault.
When transplanting the DEM, the CANbus protocol it speaks is not compatible with the rest of the car. Any module that was looking for the old DEM will therefore complain. Depending on the difference(s), different behaviors may result. For example, if your car has DSTC, it may react differently from one that doesn't have it, since DSTC looks to coordinate with the DEM.

When you test, one important thing to check for is that the DEM disengages when you put the car in reverse. Remember, just because the BCM doesn't see the DEM, the DEM may still be seeing the BCM and other modules. At least, that is what you will want, and what this reverse test will show.

What "brake module issue"?
 
#485 ·
Yes, if you have DSTC, and the DEM is not responding, you'll get BCM-0094 and this will trigger the warning shortly after powering up the car. There's no issue in the BCM however, this is the BCM raising the warning that it can't provide DSTC.
 
#487 ·
I don't have DSTC but still have BCM-0094
 
#488 ·
Yep, that can happen too. "Is what it is" since the car and especially later-year components just weren't coded for this kind of mixing and matching.
 
#489 ·
Got another data point for this thread:

2006 V50 T5 AWD M66 w/ DSTC button down by shifter
Haldex module 5Wp22228-02 from a 2005 V8 XC90

Swapped it in, had "anti-skid service required" message immediately on startup 😞

Was worth a shot. If anyone's interested in giving this unit ago, I'll send it to ya for $75 shipped
 
#507 ·
Thanks for sending one of your 2 5Wp22228-02's, Austratton.

Changed out my DEM the other day - immediately threw the dreaded "Anti-Skid Service Required" and "ABS Failure-Pull Over Safely" warnings on my 2005 V50 T5 AWD GT w DSTC.

SO - slapped the 'working' replacement DEM back in. Still get 'no communication with ECM' code when hooked up to my code reader - but AWD works (confirmed by lifting all four wheels off the ground - all turning when D engaged)

if anyone wants to try 5Wp22228-02 in their rig - PM me...yours for $75 plus shipping (what Austratton charged me).
 
#496 ·
Yes, no lights other than the normal "traction control" lights when both front tires were spinning... (facepalm)
I'm optimistic about the lack of fluid being the culprit as well. :D
(I'm going to do a full flush and filter change if it looks straight forward enough, while I'm in there)

When I get new fluid in I'll put the new solenoid back in with the old solenoid's o-rings and go from there.
 
#498 ·
The solenoids are all the same (for gen2/3) - just the pressure sensor varies depending on which version gen3
Ah! Thank you for that tidbit.

Did you lose one of the rings when you removed the original solenoid? There are three in total. That would seem to be the only reason it would be 'loose'
I did not notice the o-ring at the base of the solenoid for the original solenoid, which makes me think it is stuck up inside the Haldex diff.
The solenoid from muppetman342 has the o-ring at the base of it, and quite possibly I had them stacked one on top of the other which is why it was loose.
I have the car at the shop because the fill plug was stuck and I didn't want to bung it up with my ham-handedness.

The kicker is that the entire haldex controller filled up with oil as a result potentially breaking the controller (will do some tests when I get home from the shop). Does someone have the resistances across the pins of the chip so that I can confirm? I really doubt oil would have broken anything in the controller because oil doesn't conduct electricity, but what do I know. :D
 
#514 ·
Send me a PN if you'd consider selling it for a reasonable price :) Shipping to germany shouldn't be that much, i guess.

Oh and i found this site:

According to them the following P/Ns are for gen 3:
Code:
Volvo hap542 5wp33502-01 (Gen 3)
Volvo hap542 5wp33502-02 (Gen 3)
Volvo hap542 5wp33503-01 (Gen 3)
Volvo hap542 5wp33503-02 (Gen 3)
Volvo hap542 5wp33504-01 (Gen 3)
Volvo hap542 5wp33505-01 (Gen 3)
Volvo hap542 5wp33505-02 (Gen 3)
Volvo hap542 5wp33505-03 (Gen 3)
Did somebody test some of them, other than the ones mentioned in the OP?
33502, 33503, 33505 e.g.
 
#516 ·
Send me a PN if you'd consider selling it for a reasonable price :) Shipping to germany shouldn't be that much, i guess.

Oh and i found this site:

According to them the following P/Ns are for gen 3:
Code:
Volvo hap542 5wp33502-01 (Gen 3)
Volvo hap542 5wp33502-02 (Gen 3)
Volvo hap542 5wp33503-01 (Gen 3)
Volvo hap542 5wp33503-02 (Gen 3)
Volvo hap542 5wp33504-01 (Gen 3)
Volvo hap542 5wp33505-01 (Gen 3)
Volvo hap542 5wp33505-02 (Gen 3)
Volvo hap542 5wp33505-03 (Gen 3)
Did somebody test some of them, other than the ones mentioned in the OP?
33502, 33503, 33505 e.g.
Has to be V8 Gen3, not just Gen3 the ones in the original post are the only ones determined to work. If you have access to any of the others & want to try, can't hurt, However if any of the listed #'s are NOT V8 Gen3 application, don't waste your time.
 
#525 ·
Thanks for the link, lookforJoe. Will consider this as XEMODEX was gonna charge me $390.00 USD for a transfer (plus I would pay for used transferable DEM and shipping to/from) OR (if used transfer DEM doesn’t work) $649.00 USD plus shipping to repair my DEM (if repairable).

Volvo Dealer quoted nearly $1600.00 USD for a new DEM and software flash.

I‘ve got nearly 225,000 miles on this V50...and a working replacement DEM. Repair or New DEM would cost more than this car is worth...so really do need to decide if I’m “throwing good money after bad” to solve a DEM/ECM communication issue which doesn’t appear to affect drivability or safety.
 
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#526 ·
Any DEM issue resulting in DEM not working properly will always affect drivability and safety. In normal dry conditions the car will be about 90% FWD, it only kicks in the RWD when you need it. Ive had my XC90 kick in the RWD when I needed it in the last week on snow and ice.... and then it had a huge impact on drivability and safety.


Sent from my iPad using Tapatalk
 
#528 ·
After my DEM died and I brought my M66 T5 to the Dealer and they wanted to charge me 1500€ for a new one, I started looking for alternatives and luckily remembered this thread. Finally I had the reason to look for a Gen 3 Haldex Module.

So I spend the whole day yesterday searching the Internet and found a single 5Wp33504-01 from a 4.4L V8 XC90 in Poland with a white capped sensor on the DEM. The guy charged me 350€ for the complete Haldex Differential since he didn’t wanted to sell separately but still cheaper than even the Gen2 DEMs in Germany.

Wish me luck it works, he shipped it today :>
 
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