REMOVAL & INSTALLATION
240 Series
- Raise and safely support the vehicle.
- Remove the front wheels.
- Remove the spring clips and retaining pins. Remove the retaining springs and brake pads.
If the brake pads are difficult to remove, tool 2917 or equivalent can be used to collapse the caliper pistons to ease removal.
- Clean the caliper where the brake pads sit and inspect the dust caps for damage, and replace if necessary.
- Check the brake rotor surface for signs of wear, warping or variations in thickness.
- Compress the caliper pistons using a large pair of pliers or a C-clamp.
It may be necessary to remove some brake fluid from the reservoir when depressing the piston.
To install:-
Before replacing the pads:
- Check the rubber dust caps for the brake pistons, replace if defective. If dirt has penetrated into the cylinders, due to a defective dust cap, recondition the caliper.
- Check the friction surface of the disc, if required, replace or machine the rotor surface.
- Check the rubber seals on the guide pins, replace them if they are defective.
- Install the brake pads, retaining springs, retaining pins, and spring clips.
- Check the brake fluid level and pump the brake pedal several times. It may be necessary to bleed the brake system.
- Install the wheels.
- Check the brake pedal operation before driving the vehicle.
- Raise and safely support the vehicle.
- Remove the wheels.
- Remove the lower caliper guide pin bolt and swing the caliper upwards.
- Remove the brake pads.
Do not depress the brake pedal while pads are removed.
To install:The fluid level can rise in the reservoir when the piston is compressed.
- Remove some brake fluid to prevent spillage. Air may be trapped in the dust seal of the piston. To avoid damage to the boot, it may be necessary to release the trapped air.
- Press the piston back into the caliper.
- Inspect the piston dust cap, if it is damaged, the caliper must be overhauled or replaced.
- Check the disc brake surface for distortion or variation in thickness. Replace if not within specification.
- Check to see that the metal guide plates are in position and install the pads. Check the guide pin boots for damage and replace them if necessary.
- Swing the caliper down into position, being careful not to damage the guide pin boots. Tighten the guide pin bolt to 20 ft. lbs. (27 Nm).
- Check the reservoir fluid level and add as necessary.
- Operate the brake pedal repeatedly.
- Install the wheels.
See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 and 11
- Raise and safely support the vehicle.
- Remove the front wheels.
- Carefully remove retaining spring, without bending.
- Remove the protective caps from the guide pin bolts.
- Use an appropriate size Allen wrench (typically 7mm) to remove the guide pins.
- Remove caliper from the carrier.
- Remove the brake pads. Hang the caliper from the spring so that the hose is not damaged.
- Clean the caliper carrier where the brake pads sit.
- Check the piston dust boot for damage or dirt. If the boot is damaged, the caliper should be overhauled or replaced.
- Check the brake rotor for signs of wear or damage.
- Check the guide pin bolt rubber sleeves for damage and replace if necessary.
- Press the piston back into the caliper cylinder using a suitable tool.
- Lubricate the caliper guide pins with silicone grease.
- Insert the brake pads and slide the caliper on over them.
- Tighten the guide pins to 22 ft. lbs. (30 Nm) and replace the dust caps.
- Install the retaining spring.
- Install the wheels.
- Lower the vehicle.
- Depress the brake pedal several times and check the brake fluid reservoir level.
- Check brake pedal function before driving vehicle.
Fig. Fig. 1: Remove the retaining spring
Fig. Fig. 2: Remove the protective caps over the caliper guide pins ...
Fig. Fig. 3: ... and use an appropriate size Allen wrench (typically 7mm) ...
Fig. Fig. 4: ... to loosen and remove the caliper guide pins
Fig. Fig. 5: A large C-clamp is a useful tool to compress the piston
Fig. Fig. 6: Pull the caliper off and remove the brake pads
Fig. Fig. 7: The inboard pad is held into the caliper by metal tabs
Fig. Fig. 8: Thoroughly brush and clean the caliper carrier before replacing the pads
Fig. Fig. 9: Volvo recommends that a high temperature grease be applied to the pad contact points on the caliper carrier ...
Fig. Fig. 10: ... and caliper pins prior to pad installation
Fig. Fig. 11: Inspect the rubber sleeves for damage and cracking
INSPECTION
See Figure 12
Check the width of the brake pads using a thickness gauge, available at most auto parts stores. Minimum brake pad thickness is 0.08 inch (2mm).
Fig. Fig. 12: Pad thickness is measured from the disc to the edge of the pad
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