Volvo Coupes/Sedans/Wagons 1970-1989 Repair Guide

Brake Disc (Rotor)

Print

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Periodically inspect the brake system to ensure adequate pad and rotor thickness-these are considered normal wear items

REMOVAL & INSTALLATION



Except 700 Series

See Figures 2 through 10

  1. Loosen the lug nuts a few turns. Elevate the car and safely support on jackstands.
  2.  
  3. Remove the wheel.
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Raise and properly support the vehicle before working under it



Click image to see an enlarged view

Fig. Fig. 3: If equipped with retaining pins, drive them out with a hammer and drift



Click image to see an enlarged view

Fig. Fig. 4: With pliers, grasp and pull out the pad from its mounting position-it may be necessary to pry the pad to gain clearance from the disc



Click image to see an enlarged view

Fig. Fig. 5: Use a piece of stiff wire and hang the caliper out of the way

  1. Remove the brake pads and remove the brake caliper. Do not disconnect the brake hose running to the caliper; use a piece of stiff wire and hang the caliper out of the way.
  2.  



Click image to see an enlarged view

Fig. Fig. 6: Remove the disc retaining screws-if resistance is high, stop and apply a penetrating lubricant to loosen them for a few minutes

  1. Loosen and remove the small retaining screws on the face of the disc. They will be difficult to loosen; don't strip the heads.
  2.  



Click image to see an enlarged view

Fig. Fig. 7: If needed, apply penetrating lubricant to the mounted disc to ease removal

  1. Remove the brake disc. It may be necessary to tap on the disc with a rubber or rawhide mallet to loosen it from its place. Don't use a metal hammer; you can crack the disc.
  2.  



Click image to see an enlarged view

Fig. Fig. 8: Remove the disc-if necessary, use a soft faced hammer to lightly tap it free

  1. When reassembling, make sure the disc sits squarely on the mount and install the retaining screws.
  2.  



Click image to see an enlarged view

Fig. Fig. 9: Separate the backing plate from the pad-do not forget to reinstall it later



Click image to see an enlarged view

Fig. Fig. 10: To provide clearance for the new (thicker) pads, press the pistons into the caliper. This causes brake fluid to flow back to the master cylinder

  1. Install the brake caliper and pads. Check that the disc can turn freely and that the caliper is properly seated. Since the brake line was not disconnected, it should not be necessary to bleed the brakes.
  2.  

  1. Reinstall the wheel and lower the car to the ground. Final tighten the lug nuts to 80-90 ft. lbs. (108-122 Nm).
  2.  

700 Series

See Figure 11

  1. Loosen the lug nuts a few turns. Elevate the car and safely support on jackstands.
  2.  
  3. Remove the wheel.
  4.  
  5. Remove the brake pads and remove the brake caliper. Do not disconnect the brake hose running to the caliper; use a piece of stiff wire and hang the caliper out of the way.
  6.  
  7. Use a 10mm Allen wrench to disconnect the caliper bracket.
  8.  
  9. Remove the center grease cap, the cotter pin and the castle nut.
  10.  
  11. Remove the outer wheel bearing and place in a clean, protected location.
  12.  
  13. Remove the brake disc and the inner wheel bearing. It may be necessary to use a bearing puller (Volvo 2722 or similar) if the inner bearing is difficult to remove. Place the bearing in a clean, protected location. Remove the inner bearing seal if it remains in the hub.
  14.  

Cars with ABS have the pulse wheel mounted within the disc. This toothed wheel must be removed and transferred to a new rotor if one is being installed. Use a universal gear puller and carefully lift off the pulse wheel. Use a bearing installation tool and a press to install the pulse wheel on the new disc.

  1. When reassembling, the wheel bearings must be cleaned and repacked. The reader is referred to the Front Wheel Bearings-700 Series portion of Suspension & Steering .