Volvo 240/740/760/780/940/960 1990-1998

Brake Caliper

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REMOVAL & INSTALLATION



240 Series
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the front wheel(s).
  4.  
  5. Disconnect any ABS wires, if equipped.
  6.  
  7. Clean the caliper to ensure that no dirt gets into the brake line.
  8.  
  9. Disconnect the brake lines, and remove the two caliper mounting bolts.
  10.  

If the brake line is seized to the caliper, it should be replaced.

To install:
  1. Install the caliper using new mounting bolts.
  2.  
  3. Check the location of the caliper in relation to the disc.
    1. Use feeler gauges to check the distance between the disc and the caliper support stubs on both sides.
    2.  
    3. The difference between the two measurements must not exceed 0.001 in. (0.25mm).
    4.  
    5. Repeat the measurements using the upper and lower support stubs to check if the caliper is mounted parallel to the disc.
    6.  
    7. If the caliper is not correctly aligned, shims can be used to adjust its position.
    8.  

  4.  
  5. Install the brake pads and make sure that the disc can rotate freely between the pads.
  6.  
  7. Connect any ABS wires unfasten during removal.
  8.  
  9. Bleed the brake system.
  10.  
  11. Install the wheels.
  12.  
  13. Lower the vehicle.
  14.  
  15. Check the brake pedal function before driving vehicle.
  16.  

700 Series, 900 Series, S90 and V90 Models
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheels.
  4.  
  5. Disconnect the ABS lead and brake hose from their clips.
  6.  
  7. Clean the brake hose and line connection.
  8.  
  9. Disconnect the hose from the line.
  10.  
  11. Disconnect the hose from the caliper.
  12.  
  13. Remove the lower caliper guide pin bolt, swing the caliper up and remove the brake pads.
  14.  
  15. Remove the caliper mounting bolts and lift the caliper off.
  16.  
  17. Remove the upper caliper guide pin bolt to separate the caliper from the mounting bracket.
  18.  
  19. Clean the guide pins and inspect for wear or damage. Replace as necessary.
  20.  

To install:
  1. Lubricate the guide pins with silicone grease.
  2.  
  3. Reassemble the caliper and mounting bracket using one guide pin bolt, but do not tighten.
  4.  
  5. Install the bleed nipple and brake hose.
  6.  
  7. Mount the caliper with new bolts and tighten to 74 ft. lbs. (100 Nm).
  8.  
  9. Install the brake pads and guide pin bolt.
  10.  
  11. Tighten the guide pin bolts to 20 ft. lbs. (27 Nm).
  12.  
  13. Reconnect brake hose to line and ABS lead to the hose.
  14.  

Make sure that the brake hoses are not twisted.

  1. Bleed the brake system.
  2.  
  3. Install the wheels.
  4.  
  5. Lower the vehicle.
  6.  
  7. Check brake pedal function before driving vehicle.
  8.  

850, S70, C70 and V70 Series

See Figures 1 and 2

  1. Turn the ignition switch OFF and, if equipped with ABS, remove the key to prevent accidental pump activation.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the wheel(s).
  6.  
  7. Disconnect any ABS wires, if equipped.
  8.  
  9. Loosen the brake hose a half turn.
  10.  
  11. Remove the caliper bolts, lift the caliper off and unscrew the caliper from the hose.
  12.  
  13. Drain the remaining brake fluid from the caliper.
  14.  
  15. Remove the brake pads.
  16.  

To install:
  1. Grease the caliper bolts with lithium grease and insert them into the sleeves.
  2.  
  3. Screw the caliper onto the brake hose.
  4.  
  5. Install the brake pads and mount the caliper.
  6.  
  7. Tighten the caliper bolts to 22 ft. lbs. (30 Nm) and install the dust caps.
  8.  
  9. Install the retaining clip.
  10.  
  11. Tighten the brake hose to 13 ft. lbs. (18 Nm).
  12.  

Make sure that the brakes hose is not twisted.

  1. Fill the master cylinder and bleed the brake system. Check the system for leaks and proper function.
  2.  
  3. Connect any ABS wires which were previously removed.
  4.  
  5. Install the wheels.
  6.  
  7. Lower the vehicle.
  8.  
  9. Check the brake function before driving the car.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Loosen and remove the caliper carrier retaining bolts, usually using a 17mm socket or wrench ...



Click image to see an enlarged view

Fig. Fig. 2: ... and remove the caliper carrier

OVERHAUL



See Figures 3, 4, 5, 6, 7, 8, 9 and 10

Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

  1. Remove the caliper from the vehicle and place on a clean workbench.
  2.  


CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!

Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

  1. The first method is as follows:
    1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
    2.  
    3. Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.

      Click image to see an enlarged view

      Fig. Fig. 3: For some types of calipers, use compressed air to drive the piston out of the caliper, but be sure to keep your fingers clear



      Click image to see an enlarged view

      Fig. Fig. 4: Withdraw the piston from the caliper bore

    4.  

  2.  
  3. For the second method, you must rotate the piston to retract it from the caliper.
  4.  
  5. If equipped, remove the anti-rattle clip.
  6.  



Click image to see an enlarged view

Fig. Fig. 5: On some vehicles, you must remove the anti-rattle clip

  1. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
  2.  



Click image to see an enlarged view

Fig. Fig. 6: Use a prytool to carefully pry around the edge of the boot ...



Click image to see an enlarged view

Fig. Fig. 7: ... then remove the boot from the caliper housing, taking care not to score or damage the bore

  1. Remove the piston seals from the groove in the caliper bore.
  2.  



Click image to see an enlarged view

Fig. Fig. 8: Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

  1. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
  2.  
  3. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
  4.  
  5. Use crocus cloth to polish out light corrosion from the piston and bore.
  6.  
  7. Clean all parts with denatured alcohol and dry with compressed air.
  8.  

To assemble:
  1. Lubricate and install the bleeder valve and cap.
  2.  
  3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
  4.  
  5. Lubricate the piston bore.
  6.  
  7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
  8.  
  9. Use a suitable driving tool to seat the boots in the housing.
  10.  



Click image to see an enlarged view

Fig. Fig. 9: Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

  1. Install the caliper in the vehicle.
  2.  
  3. Install the wheel and tire assembly, then carefully lower the vehicle.
  4.  
  5. Properly bleed the brake system.
  6.  



Click image to see an enlarged view

Fig. Fig. 10: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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