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

Brake Disc (Rotor)

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REMOVAL & INSTALLATION



240 Series
  1. Raise and safely support vehicle.
  2.  
  3. Remove the wheel(s).
  4.  
  5. Remove the brake caliper and hang it from the spring with a piece of wire.
  6.  
  7. Remove the two screws securing the disc.
  8.  
  9. Lift off the disc; it may be necessary to tap on the disc with a soft-faced hammer.
  10.  

To install:
  1. Install the new disc, make sure the mating surfaces of the disc and hub are clean and dry.
  2.  
  3. Install the caliper using new mounting bolts.
  4.  
  5. Check the location of the caliper in relation to the disc. Use feeler gauges to check the distance between the disc and the caliper support stubs on both sides. The difference between the two measurements must not exceed 0.001 in. (0.0013mm). Repeat the measurements using the upper and lower support stubs to check if the caliper is mounted parallel to the disc. If the caliper is not correctly aligned, shims can be used to adjust the caliper's position.
  6.  
  7. Install the brake pads and make sure that the disc can rotate freely between the pads.
  8.  
  9. Install the disc securing screws.
  10.  
  11. Install the wheels.
  12.  
  13. Lower the vehicle.
  14.  
  15. Check brake pedal function before driving vehicle.
  16.  

700 Series, 900 Series, S90 and V90 Models
  1. Raise and safely support vehicle.
  2.  
  3. Remove the wheel(s).
  4.  
  5. Remove the caliper and brake pads.
  6.  
  7. Hang the caliper on the spring to prevent damaging the brake hose.
  8.  
  9. Remove the locating pin and tap the disc off with a plastic mallet if stuck.
  10.  
  11. Clean the axle shaft flange, remove all corrosion and dirt.
  12.  

To install:
  1. Install the new disc making sure that the friction surfaces on both sides are clean.
  2.  
  3. Install the locating stud and tighten to 72 inch lbs. (8 Nm).
  4.  
  5. Install the caliper using new bolts, then install the brake pads.
  6.  
  7. Install the wheels.
  8.  
  9. Lower the vehicle.
  10.  

850, S70, C70 and V70 Series

See Figures 1, 2 and 3

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheel(s).
  4.  
  5. Remove the brake pads and shims.
  6.  
  7. Remove the two caliper and disconnect the brake line from its clip.
  8.  
  9. Remove the brake caliper and hang it from the spring to prevent damaging the line.
  10.  
  11. Loosen the parking brake adjuster slightly so the disc a can be removed.
  12.  
  13. Remove the wheel guide pin bolt and disc.
  14.  

To install:
  1. Clean the face of the hub and check it for signs of damage. If the hub shows signs of damage, check the run-out by:
    1. Mounting a dial indicator and rotating the hub with sensor tip on the face of the hub.
    2.  
    3. If the highest spot on the hub is higher than 0.007 in. (0.20mm), the hub must be replaced.
    4.  

  2.  
  3. Carefully brush the ABS pulse wheel off with a soft brush.
  4.  
  5. Install the brake disc and guide pin bolt.
  6.  
  7. Tighten the bolt to 72 inch lbs. (8 Nm).
  8.  
  9. Install the caliper and pads, using new mounting bolts.
  10.  
  11. Install the brake line and mounting clip.
  12.  
  13. Depress the brake pedal several times and check the brake fluid reservoir.
  14.  
  15. Adjust the parking brake.
  16.  
  17. Install the wheels.
  18.  
  19. Lower the vehicle.
  20.  
  21. Check the brake function before driving the vehicle.
  22.  



Click image to see an enlarged view

Fig. Fig. 1: Use the appropriate size wrench to loosen ...



Click image to see an enlarged view

Fig. Fig. 2: ... and remove the wheel guide pin bolt



Click image to see an enlarged view

Fig. Fig. 3: Remove the brake disc; if stuck, lightly tap with a soft-faced hammer to loosen it

INSPECTION



Inspect the brake rotor for scoring and wear; minor scoring or disc pad lining build-up does not require rotor machining or replacement. If heavy scoring, cracks or other damage is evident, replace or have the rotor machined, as necessary.

Glaze on the rotor can be removed by hand-sanding it with medium grit garnet paper or aluminum oxide sandpaper.

The minimum thickness of each brake rotor is indicated on the rotor itself. Do not utilize a rotor which is worn below the minimum allowable thickness. If rotor damage cannot be corrected by grinding to these minimums, the rotor must be replaced.

Rotor lateral run-out must not be more than 0.001 in. (0.035mm).

 
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