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 wheels.
  4.  
  5. Remove the guard plate, if equipped.
  6.  
  7. Disconnect any ABS wires, if equipped.
  8.  
  9. Disconnect the brake line from the rear axle and remove the mounting bolts for the caliper.
  10.  
  11. Disconnect the brake line from the caliper and remove the caliper.
  12.  
  13. Remove the brake pads.
  14.  

To install:
  1. Attach the brake line loosely to the caliper.
  2.  
  3. Install the caliper using new mounting bolts.
  4.  
  5. Check the position of the caliper in relation to the disc as follows:
    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.  

  6.  
  7. Tighten the bleed screw and line.
  8.  
  9. Attach the brake line to the rear axle.
  10.  
  11. Install the brake pads.
  12.  
  13. Connect any ABS wires unfastened earlier.
  14.  
  15. Bleed the brake system.
  16.  
  17. Install the wheels.
  18.  
  19. Lower the vehicle.
  20.  
  21. Check brake function before driving the vehicle.
  22.  

700 Series, 900 Series, S90 and V90 Models
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheels.
  4.  
  5. Disconnect any ABS wires, if equipped.
  6.  
  7. Clean the brake hose and line connection. Disconnect the hose from the line. Disconnect the hose from the caliper.
  8.  
  9. Disconnect the parking brake cable from the bracket.
  10.  
  11. On models with an independent rear axle, do the following;
    1. Remove the caliper retaining bolt and swing the caliper up. Remove the brake pads.
    2.  
    3. Unfasten the two caliper bolts and remove the caliper.
    4.  
    5. Mount the caliper in a vise. Remove the remaining guide pin retaining bolt and separate the caliper from its retainer.
    6.  

  12.  
  13. On models with a solid rear axle, do the following;
    1. Remove the guide pins using a 3mm punch.
    2.  
    3. Remove the dampening spring, and brake pads.
    4.  
    5. Unfasten the caliper mounting bolts and remove the caliper.
    6.  

  14.  

To install:
  1. On models with an independent rear axle, do the following;
    1. Clean the caliper retainer and install new rubber sleeves. Lubricate the guide pins with silicone grease. Reassemble the caliper and retainer using one retainer bolt, but do not tighten.
    2.  
    3. Install the caliper using new bolts and tighten them to 43 ft. lbs. (58 Nm). Install the brake pads. Swing the caliper down and install the lower caliper guide pin retaining bolt and tighten them both to 25 ft. lbs. (34 Nm).
    4.  

  2.  
  3. On models with a solid rear axle, do the following;
    1. Lubricate the shims and install the brake pads.
    2.  
    3. Install one fluid pin, and a new dampening plate. Then install the other guide pin.
    4.  

  4.  
  5. Connect the brake hose, caliper and brake line.
  6.  
  7. Connect the parking brake cable to the bracket.
  8.  
  9. Connect any ABS wires, unfastened earlier.
  10.  

Make sure the hose is not twisted between the caliper and line.

  1. Bleed the brake system using upper nipple.
  2.  
  3. Install the wheels.
  4.  
  5. Lower the vehicle.
  6.  

850, S70, C70 and V70 Series

See Figures 1, 2, 3, 4, 5 and 6

  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. Clean the brake caliper thoroughly and remove the dust caps from the bleeder nipple.
  10.  
  11. Open the bleed nipple and lock the brake pedal the depressed position. Collect the brake fluid spillage in a suitable container.
  12.  
  13. Remove the brake pads and disconnect the brake pipes from the caliper.
  14.  
  15. Remove caliper mounting bolts and lift the caliper off.
  16.  
  17. Drain the remaining brake fluid in the caliper into suitable container.
  18.  

To install:
  1. Clean the caliper mount where the caliper lies.
  2.  
  3. Install the caliper and new mounting bolts. Tighten the bolts to 44 ft. lbs. (60 Nm).
  4.  
  5. Connect the brake line to the caliper and tighten to 10 ft. lbs. (14 Nm).
  6.  
  7. Grease the brake pad shims with a thin layer of silicon grease. Put the shims on the back of the pads and install them in the caliper.
  8.  
  9. Install one retaining pin, spring then the other retaining pin.
  10.  
  11. Fill the brake master cylinder and bleed the brake system.
  12.  
  13. Connect any ABS wires, unfastened earlier.
  14.  
  15. Install the wheels.
  16.  
  17. Lower the vehicle and check the brake function before driving.
  18.  



Click image to see an enlarged view

Fig. Fig. 1: To avoid damaging the fastener, be sure to use the correct size flare nut or line wrench to disconnect the brake line



Click image to see an enlarged view

Fig. Fig. 2: After the brake line is loosened, remove it from the caliper ...



Click image to see an enlarged view

Fig. Fig. 3: ... and plug the brake line to prevent dirt from entering



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Fig. Fig. 4: Unfasten the brake caliper mounting bolts ...



Click image to see an enlarged view

Fig. Fig. 5: ... then remove the caliper



Click image to see an enlarged view

Fig. Fig. 6: Volvo recommends that you spread a small amount of threadlocking compound on the caliper mounting bolts

OVERHAUL



See the Front Brake Caliper overhaul procedure, earlier in this section.

 
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