Went into my mechanic with my '95 960 wagon (111,000 miles) having an underbody rattle and vibration. He identified a worn CV joint between the drive shaft and axle. He called Volvo and was told the company no longer sells that CV joint and offered the new recommended fix, the entire drive shaft assembly and differential flange (system used in '97 and newer) with a traditional U joint for $1,150.
Does anyone out there have advice on a lower-cost solution? The $1,150 isn't in my family's budget. The mechanic suggests there might be a close enough CV joint match with a replacement for another vehicle. Or he says we might find a '97 or newer used shaft assembly. Or we might find a good used CV joint from the '95 or 96' model years. The other option he's thinking about is machining the end of the existing shaft to take the joint currently specified for the car.
I would greatly appreciate any advice on the best solution and/or where I might find the parts necessary to make the fix in a more economical manner.
My mechanic works mostly on Volvos and he's very disappointed with the answer he got from the manufacturer. He thinks there must be a better answer than replacing the entire drive shaft assembly, which is otherwise in great condition.
Thanks in advance for any help!

Thanks to everyone who shared their advice on the drive shaft CV joint for my '95 960. Here's how the fix went down: My mechanics took a number off the original joint and traced it to a multipurpose CV joint made by LOBRO (I think that's the correct name). While Volvo wouldn't sell just the joint (they wanted to sell a $1,200 drive shaft assembly with joint), a seller of Lobro parts somewhere out East would sell just the joint, which cost $190 shipped (ouch). When the part came, it was slightly longer than the original due to an extended lip at one end. Had that machined to the right fit at a local shop ($60). Labor was 3.75 hours, so the whole repair cost $525. It would have been cheaper to buy a used shaft with joint for about $150 shipped, but it could have also been worn out. The whole thing took about a week given the runaround. The mechanic said he would see me in another year ... But unfortunately, the radio died right after I left his shop. But that's for another post.

Whatta ya know! My first post replying to someone else with a problem! (Usually I'm just perusing your posts, gleaning information . . . to much of a newbie to contribute much). However, I have a '95 960 which had the same problem, so . . .

You're correct, you have a CV joint instead of a U-joint at the rear of your driveshaft. While you may be able to clean yours and repack it with grease, mine was too far gone for that. My mechanic was also unsuccessful in finding someone other than the dealer who sold it; and our local dealer wanted over $300USD.
To make a long story short, after MUCH searching i found the Volvo part number is 271382; it is a CV joint kit. I can't find the record showing where I purchased it from, but Volvopartsdirect.com has it listed for $269USD, manufactured by EPD. My mechanic installed it for $125 (This included him changing out the center support housing and bearing, and all U-joints, hopefully effectively rebuilding my drive shaft). Please double check that part number I gave you, but rest assured, that joint is sold seperately, and is an option for you. Good luck . . .

I would go to a truck repair parts shop that has a drive shaft repair section. If they cant match it, they can make a whole new end. I have had several different drive shafts made. The most expensive one was for an 78 caddilac, at 178.00 that was new ends, joints, and balanced. Just make sure you bring them the flange part that matches your diff. flange. I'm sure any competant drive shaft guy would have you running by the end of the day.

http://www.mesadriveshaft.com/

A place like this, for example....

A truck/bus/heavy equipment/ farm equipment driveshaft service can, if necessary, cut your shafts and weld in a functional equivalent if a part really isn't available. It would just have to fit the space. Driveshafts are rebuilt all the time in heavy service. Ask the local schoolbus or garbage truck people who does their their shaft work.

Your mechanic is correct. I never knew what the price was but I knew it was very expensive. And a whole new design at that. Yes there is a CV joint, at the end of the driveshaft. When it wears out the whole shaft has to be replaced. Not a very user friendly design I will admit. There maybe some old posts involving this subject. I recall that someone had a clicking noise when accelerating, they discovered that the grease had dried out of the joint. They were lucky in that all they had to do was clean the joint out and repack with some expensive grease. I would look for one from a bone yard. This item does not seem to have a high failure rate based on the few posts here.

Let us know what you decide.

DanR 94 964 221,000 miles
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DanR

I'm not entirely sure which part the mechanic is referring to, because I don't think there is a CV joint in the driveshaft. There should be a U-joint on the rear of the driveshaft, if I am not mistaken. All OEM Volvo Parts (www.alloemvolvoparts.com) has the U-Joints for $16. Here:

U-Joint
K1010-31548
In Stock $44.26 retail 15.52 internet price

There is a picture of the U-joint on the website, too.

I'm sure the other parts places have them also (FCPGroton, GAPA, etc.).

Have your mechanic see if this is the part he needs. Hope this helps.

Mike Brown
Greenville, NC
1996 965 94K
1986 244 137K

Regarding the correct info on the cv joint; Yes, the mechanic showed me the cv joint. It was used in 94 and 95 models, then discontinued and Volvo went back to the traditional u-joint, which was, apparently a reliable design in the first place.One post mentioned packing with grease, but what if it doesn't have a grease fitting?

Well I'll be. Had no idea that they used a CV joint for those years. In this case then read the FAQ story with answer here:
http://www.brickboard.com/FAQ/700-900/960_90Info.htm#960DrivelineNoiseFailingGreaseSealatRearofDriveshaft

It gives you some ideas about how to do it (or how to have your mechanic repair it). Hope that all it needs is a good repack with CV joint grease. Let us know....

Mike

If there is no grease fitting, you can usually work grease in past a seal with a large animal (i.e. horse) syringe with a large needle .
The grease used in CV joints is a special thin easy flowing variety usually.it can be found at shops that rebuild the things .
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-------Robert, '93 940t, '90 240 wagon, '84 240 diesel (she's sick) , '80 245 diesel

Your subject line seems totally adequate. U-joints should be one of the last parts Volvo doesn´t stock for old models. Try another dealer/garage.

With the proliferation of frontwheel drive and 4X4 vehicles, many transmission shops have gone to servicing drive lines along with the transmissions.
I had the occasion to help my son with a bad driveline in his BMW.
We took the driveshaft out of the car and took it to a driveline shop and they rebuilt the whole thing with generic u-joints. I think they just cut the flanges off the shafts and welded new attachment points.
Seems to me that it cost somewhere around two hundred bucks. It included a computerized balance.
The shop owner told me the BMW dealer would have installed a whole new driveline for seven or eight hundred. (This was about three years ago.)
Check around. Good luck.