I have had ongoing maintenance issues with this vehicle and I just want to get some opinions about whether this thing is just a lemon or if the dealer is just celebrating the latest in a long line of suckers.

Issue #1 brakes seem to need to be changed as often as oil:
The front brakes seem to NEVER show much wear, but I only get about 10K out of the rear pads. Seems counter to everything I know about braking weight distribution etc. The service folks just don't have an answer, but don't act like its that unusual. Seems to me the front brakes should be working harder than the rears, but they dont seem to be wearing AT ALL.

Issue#2 Bevel Gear Seals
For the 2nd time in 15K we have a bevel gear leak and to the tune of $500+. again, shoulders go up and down and blank looks are provide at no extra charge. Seems also that there may be an underlying problem that is not being addressed/investigated.

Please any feedback/head slaps would be much appreciated. Our kids future college education is on the line...

The first generation XC cars do use more rear brakes than front, usually at about a 2x ratio of rear pads to front pads -- the lifespan of rear pads is generally in the 20 - 30K miles range with 20 - 25K being common. This is caused by the very small pads used on the rears wearing much faster than the fronts due to their smaller surface area.

The bevel gear should not leak. When fixed it should stay fixed. I assume that the leak is coming from the bevel gearbox-to-transmission seal, so fixing should be a matter of remove bevel gearbox, install new seal, no more leak.

In regards to the rear brakes, check to see if the ABS light is not burned out. The ABS controller distributes pressure and if not working will cause the rear pads to contact first. Also a good time to flush your brake lines with new fluid. And, no, this is hardly normal or even remotely common. Time to find a good indie and dump the dealer.
AWD seals. Make sure you rotate the tires front to back every 5-6,000 miles to keep the tread wear even. Check the pressure, too. Any inbalance with the wheels will cause the fluids to overheat. Of course, all tires must be the same brand and size. My dealer would kick ME in the butt if I had mixed tires on the car.
Again, there are a lot of independents where you live, find a good one. Check the "shops" listing on this site.

Klaus
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(V♂LV♂s 1975 164, 1995 854T, 1998 V70R)

Klaus,

Thanks for the feedback. The ABS light does light (first thing I checked). I will get the brake fluid flushed. All tires are same make/model and are rotated every 5K. Any other thoughts on these issues? Is this rig just haunted?

It's possible that the slides are full of dirt and need to be cleaned, but a brake fluid flush can never hurt. Just be easy on the master cylinder.

Klaus
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(V♂LV♂s 1975 164, 1995 854T, 1998 V70R)

It is quite simple to check the brake force distribution;
1. drive and do some distinct but not hard braking, stopping once or twice from highway speed is sufficient
2. check the temperature of the rotors with your finger (but be careful)
Front rotors shall be about twice as hot as rear and there shall be no noticeable difference between left and right on an axle

re: "...check the temperature of the rotors with your finger (but be careful)
..."

To avoid a burned finger tip, get a RayTek IR thermometer -- point it at the rotor between the wheel spokes, and you read the temperature on a digital display to the nearest 1/10 degree.

About $90 from IPD and many other mailorder houses (e.g., Griot's Garage).