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

Cables

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REMOVAL & INSTALLATION



240 Series
  1. Apply the parking brake.
  2.  
  3. Remove the hub caps for the rear wheels and loosen the lug nuts a few turns.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the wheel and tire assembly.
  8.  
  9. Release the parking brake.
  10.  
  11. Remove the bolt and the wheel from the pulley.
  12.  
  13. Remove the rubber cover for the front attachment of the cable sleeve and nut, as well as the attachment for the rubber suspension ring on the frame.
  14.  
  15. Remove the cable from the other side of the attachment in the same manner.
  16.  
  17. Hold the return spring in position. Pry up the lock and remove the lock pin so the cable releases form the lever.
  18.  
  19. Remove the return spring with washers.
  20.  
  21. Loosen the nut for the rear attachment of the cable sleeve.
  22.  
  23. Lift the cable forward after loosening both side of the attachments and remove it.
  24.  

To install:
  1. Adjust the rear brake shoes of the parking brake by removing the rear ashtray between the front seat backs.
  2.  
  3. Tighten the parking brake cable adjusting screw so the brake is fully applied when pulled up 2-3 notches.
  4.  
  5. If one cable is stretched more than the other, they can be individually adjusted by removing the parking brake cover (2 screws) and turning the individual cable adjusting nut at the front of each yoke pivot.
  6.  
  7. Install the ashtray and parking brake cover, if equipped.
  8.  
  9. Install new rubber cable guides for the cable suspension.
  10.  
  11. Place the cable in position in the rear attachment and tighten the nut.
  12.  
  13. Install the washers and return spring.
  14.  
  15. Oil the lock pin and install it, together with the cable, on the lever.
  16.  
  17. Install the attachment and rubber cable guide on the frame.
  18.  
  19. Install the cable in the same manner on the side of the vehicle.
  20.  
  21. Place the cable sleeve in position in the front attachments and install the rubber covers.
  22.  
  23. Lubricate and install the pulley on the pull rod.
  24.  
  25. Adjust the pulley so the parking brake is fully engaged with the lever at the 3rd or 4th notch.
  26.  
  27. Install the wheel and tire assemblies.
  28.  
  29. Lower the vehicle.
  30.  

Except 240 Series
SHORT CABLE-RIGHT SIDE
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the passenger side rear wheel.
  4.  
  5. Remove the right brake caliper and hang it from the coil spring with a wire.
  6.  
  7. Remove the brake disc.
  8.  
  9. Unhook the rear return spring and remove the brake shoes.
  10.  
  11. Push out the pin holding the cable to the brake lever.
  12.  
  13. Remove the rubber bellows (boot) from the backing plate and remove the bellows from the cable.
  14.  
  15. Remove the spring clip, pin and cable from the back of the differential housing.
  16.  
  17. Remove the cable guide on the differential by removing the top bolt from the housing cover.
  18.  
  19. Remove the cable.
  20.  

To install:
  1. Install the cable guide on the new cable.
  2.  
  3. Check the rubber bellows for wear or damage and replace if necessary. Install the bellows and position it through the hole in the backing plate. Make sure the bellows sits correctly on the backing plate.
  4.  
  5. Smear the contact surfaces of the brake levers with a thin layer of heat resistant graphite grease.
  6.  
  7. Connect the cable to the lever and install the pin.
  8.  

The arrow stamped on the lever should point upward and outwards.

  1. Push the cable through and place the lever in position behind the rear axle flange.
  2.  
  3. Install the cable guide on the axle.
  4.  
  5. Connect the cable to the equalizer using the pin and spring clip.
  6.  
  7. Install the brake shoes and rear return spring.
  8.  
  9. Install the brake disc and caliper. Use new bolts. and tighten to 43 ft. lbs. (58 Nm). Make sure the disc rotates freely.
  10.  
  11. Adjust the parking brake.
  12.  
  13. Install the wheel.
  14.  
  15. Lower the vehicle.
  16.  

LONG CABLE-LEFT SIDE

See Figures 1 and 2

  1. Remove the center console.
  2.  
  3. Slacken the parking brake adjusting screw.
  4.  
  5. Remove the cable lock ring and remove the cable.
  6.  
  7. Pull out the cable from the spring sleeve.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove the driver side rear wheel.
  12.  
  13. Remove the left rear brake caliper and hang it from the coil spring with a piece of wire.
  14.  
  15. Remove the brake disc and rear return spring.
  16.  
  17. Remove the brake shoes.
  18.  
  19. Push out the pin holding the cable to the lever.
  20.  
  21. Remove the rubber bellows from the backing plate and remove the bellows from the cable.
  22.  
  23. Pull out the cable from the backing plate and the equalizer on top of the rear axle.
  24.  
  25. Remove the cable clamp on the sub-frame, above the driveshaft, and the cable.
  26.  

To install:
  1. Install the new cable through the grommet in the floor; check that the grommet sits correctly.
  2.  
  3. Clamp the cable to the sub-frame.
  4.  
  5. Smear the contact surfaces of the brake levers with a thin layer of heat resistant graphite grease.
  6.  
  7. Connect the cable to the lever and install the pin.
  8.  

The arrow stamped on the lever should point upward and outwards.

  1. Push the cable through and place the lever in position behind the rear axle flange.
  2.  
  3. Install the cable guide on the axle.
  4.  
  5. Connect the cable to the equalizer using the pin and spring clip.
  6.  
  7. Install the brake shoes and rear return spring.
  8.  
  9. Install the brake disc and caliper. Use new bolts. and tighten to 43 ft. lbs. (58 Nm). Make sure the disc rotates freely.
  10.  
  11. Adjust the parking brake.
  12.  
  13. Install the wheel.
  14.  
  15. Lower the vehicle.
  16.  



Click image to see an enlarged view

Fig. Fig. 1: Parking brake and cable exploded view



Click image to see an enlarged view

Fig. Fig. 2: Release the tension on the cable by backing off the bolt on the handle

ADJUSTMENT



See Figures 3, 4 and 5

  1. The parking brake should be fully applied when the handle is moved no more than ten notches. If adjustment is required, adjust the brake shoes first.
  2.  
  3. For 850 models, full braking should be reached when the handle is raised about five notches. If cable adjustment is required:
    1. Remove the square cover plate under the armrest in the middle console.
    2.  
    3. Turn the adjustment screw so that full braking is obtained between the second and eighth notch.
    4.  
    5. Replace the square cover plate.
    6.  

  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the rear wheels.
  8.  
  9. With the brake handle released, install a brake adjusting tool through the hole in the rotor between the studs.
  10.  
  11. Turn the adjuster wheel until the rotor will not turn.
  12.  
  13. Loosen the adjuster wheel 4-5 notches.
  14.  
  15. Make sure the rotor turns freely. If the shoes are binding inside the rotor even after loosening the adjuster more, remove the rotor to repair the problem.
  16.  
  17. Move the handle again: adequate braking power should be obtained at 3-7 notches with a normal pull force of approximately 65 lbs. (84 Nm). If cable adjustment is required, remove the access panel behind the brake handle and adjust through the opening in the rear console.
  18.  
  19. The yoke on top of the brake handle should be at right angles to the parking brake lever. If the yoke is out of alignment, lower the handle and turn the nuts at the cable ends to adjust. There should always be at least 0.1 inch (2mm) thread protruding.
  20.  
  21. Make sure the indicator light on the instrument panel illuminates when the brake is applied.
  22.  



Click image to see an enlarged view

Fig. Fig. 3: The parking brake is adjusted through an opening in the rotor on 850/C70/S70/V70 models



Click image to see an enlarged view

Fig. Fig. 4: Parking brake adjustment on 240, Coupe and 700 series models



Click image to see an enlarged view

Fig. Fig. 5: Parking brake adjustment on 900 series models

 
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