Volvo Coupes/Sedans/Wagons 1970-1989 Repair Guide

Brake Caliper

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REMOVAL & INSTALLATION



See Figure 1

  1. Loosen the lug nuts a few turns. Block the reservoir cap vent hole to reduce leakage of brake fluid when the lines are disconnected. Firmly apply the parking brake.
  2.  



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Fig. Fig. 1: With the pads removed, remove the bolts, then disconnect the brake line and the caliper

  1. Raise the front end and place jackstands beneath the front jack attachments. Remove the wheel.
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  3. On 140 series and 164 models, remove the brake hose retaining clip from the stabilizer bar and disconnect the lower hose and brake line from their connection underneath the car. Disconnect the upper hose from the caliper. Plug all brake connections to prevent leakage.
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  5. On 1800, 200 and 700 Series, label and disconnect the brake lines at the caliper and plug them.
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  7. Remove the two caliper attaching bolts and lift the unit off the retainer.
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  9. To install, first check the mating surfaces of the caliper and its retainer to make sure that they are clean and not damaged. Always use new retaining bolts and lightly coat the threads with a locking compound. Position the caliper to its retainer over the disc and install the two attaching bolts. For all vehicles except 700 Series, tighten the bolts to 65-70 ft. lbs. (88-95 Nm). The mounting bolts on 700 Series cars should be tightened only to 25 ft. lbs. (34 Nm). Install the brake pads (if not already done), making sure that the caliper is parallel to the disc and that the disc can rotate freely in the brake pads.
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  11. On 140 series and 164 models, connect the lower brake hose and the brake line to their inboard connection and install the brake hose retaining clip to the stabilizer bar. Connect the upper brake hose to the caliper.
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  13. On 1800, 240, 260 and 700 Series, connect both brake lines to the caliper.
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  15. Unplug the reservoir cap vent hole. Install the wheel and lower the car to the ground. Tighten the lug nuts to 80-90 ft. lbs. (108-122 Nm).
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  17. Bleed the brake system as outlined in this section.
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OVERHAUL



See Figures 2 through 7

The following procedure applies to front and rear calipers of both Girling and ATE design.

  1. Remove the brake caliper and pads from the car.
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  3. Remove the retaining rings and the rubber dust covers. Place a wooden block between the pistons. Using compressed air applied through the brake line port, force the pistons toward the wooden block. Remove the pistons from their bores, taking care not to burr or scratch them.
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Fig. Fig. 2: Remove the retaining rings and the rubber dust covers from the pistons-front 4-piston caliper shown; the procedure is common to all Volvo calipers

Compressed air is the only reliable way to force out the pistons. Do not attempt to lever or pry out the pistons. The metal will become gouged and function will be impaired.



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Fig. Fig. 3: With a wooden block installed, use compressed air to force the pistons out of their bores



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Fig. Fig. 4: Remove the pistons for inspection

  1. Remove the sealing rings with a blunt plastic tool. Be careful not to damage the edges of the grooves. Screw out the bleeder nipple(s), and on front calipers, remove the external connecting line if still attached.
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Fig. Fig. 5: Remove the seals with a small prytool


WARNING
Do not attempt to separate the caliper halves. Assembling the halves requires special pressure testing equipment. Overhaul can be completed without splitting the caliper.

  1. Clean all reusable metal parts in clean brake fluid or methylated alcohol. Dry all parts with compressed air or allow to air dry. Make sure that all of the passages are clear. All alcohol must be removed from the parts. If any of the cylinders are scored or scratched, the entire housing must be replaced. Minor scratching may be removed from the pistons by fine polishing. Replace any piston that is damaged or worn.
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  3. Coat the mating surfaces of the pistons and cylinder with fresh brake fluid.
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  5. Install new sealing rings in the cylinders.
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  7. On Girling brakes and ATE front brakes, press the pistons into their bores with the large end facing inward. Make sure that the pistons are installed straight and are not scratched in the process.
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  9. On ATE rear brakes, make sure that the pistons are in the proper positions to prevent brake squeal. The piston notches should incline 20° in relation to the lower guide area on the caliper. Check the location of the piston with a template such as Volvo tool 2919. When the template is placed against the one recess, the distance (A) to the other recess may be no greater then 0.039 in. (1mm). If the location of the piston needs adjusting, use Volvo tool 2918 or similar and press it against the piston. Force out the shoes by screwing in the handle. Turn the piston in the required direction, release the tool and remeasure with the template. Repeat this operation for the other piston.
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Fig. Fig. 6: Check that the ATE rear caliper pistons are located within specification-special Volvo tool shown

  1. Place the new rubber dust covers on the pistons and housing. Install the new retaining rings.
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Fig. Fig. 7: Adjust the ATE rear caliper pistons to the proper tolerance

  1. Screw in the bleeder nipples(s).
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  3. Install the assembled caliper, then install the brake pads. Connect the brake line(s).
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  5. Add brake fluid to the reservoir to replace that lost during removal. Bleed the brake system.
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