Volvo Coupes/Sedans/Wagons 1970-1989 Repair Guide

Cables

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See Figure 1



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Fig. Fig. 1: Brake lever assembly-a dual cable system is used to actuate the (dedicated) right and left rear parking brake shoes

ADJUSTMENT



1800, 140 and 160 Series

See Figures 2, 3 and 4

The parking brake should be fully engaged when the lever is pulled up to the third or fourth notch. If it is not, adjust as follows:

  1. Apply the parking brake. Remove the rear hub caps and loosen the lug nuts a few turns.
  2.  
  3. Place blocks in front of the front wheels. Jack up the rear end and place jackstands beneath the rear axle. Remove the wheel. Release the parking brake.
  4.  
  5. Make sure that the brake pads are not stuck on the discs. Disconnect the parking brake cable from the actuating lever. This keeps the pre-tension off the brakes while you adjust them.
  6.  
  7. Rotate the disc until the adjusting screw hole aligns with the serrations (ridges) on the adjusting wheel inside the disc. Insert a screwdriver, and adjust the shoes by moving the handle of the screwdriver upward. When the disc cannot be rotated easily, stop adjusting the shoes. Turn the adjusting screw back 4 or 5 serrations. Turn the disc in its normal direction of rotation and make sure that the shoes do not drag. A slight brushing is permissible, but if there is heavy drag, back off the adjusting screw 2 or 3 serrations more. Connect the cable to the lever.
  8.  



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Fig. Fig. 2: Parking brake components found on all 1970-74 models

  1. Repeat the adjusting procedure for the other wheel.
  2.  



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Fig. Fig. 3: Adjust the parking brake through the access hole in the rear hub

  1. Apply the parking brake lever and make sure that the parking brake is fully engaged with the lever at the third or fourth notch. If the brakes are properly adjusted but don't apply fully, adjust the cable:
    1. Locate the cable yoke assembly under the car. It is the device that pulls simultaneously on both the left and right brake cables.
    2.  
    3. Loosen the two locknuts on the threaded shaft. The shaft will probably be dirty and rusted. Be prepared to clean the threads.
    4.  
    5. Tighten the adjusting nut (the one that bears on the spring) a few turns and recheck the lever in the car. Continue adjusting until the brakes are fully applied at the third or fourth notch.
    6.  
    7. Tighten both locknuts. While you're under there, clean the pulley wheel and apply a light coat of oil to its axle.
    8.  

  2.  



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Fig. Fig. 4: Exploded view of the parking brake assembly-1975 and later models

Do not attempt to adjust the parking brake only by tightening the cable. The brake shoes must be properly adjusted before the cable is tightened.

  1. Install the wheels. Remove the jackstands and lower the car. Tighten the lug nuts to 80-90 ft. lbs. (108-122 Nm).
  2.  

200 Series
  1. Apply the parking brake. Remove the rear hub caps and loosen the lug nuts a few turns.
  2.  
  3. Place blocks in front of the front wheels. Jack up the rear end and place jackstands beneath the rear axle. Remove the wheel. Release the parking brake.
  4.  
  5. Make sure that the brake pads are not stuck on the discs.
  6.  
  7. Rotate the disc until the adjusting screw hole aligns with the serrations (ridges) on the adjusting wheel inside the disc. Insert a screwdriver and adjust the shoes by moving the handle of the screwdriver upward. When the disc cannot be rotated easily, stop adjusting the shoes. Turn the adjusting screw back 4 or 5 serrations. Turn the disc in its normal direction of rotation and make sure that the shoes do not drag. A slight brushing is permissible, but if there is heavy drag, back off the adjusting screw two or three serrations more.
  8.  
  9. Repeat the adjusting procedure for the other wheel.
  10.  
  11. Apply the parking brake lever and make sure that the parking brake is fully engaged with the lever at the second and eighth notch. If the brakes are properly adjusted but don't apply fully, adjust the cable:
    1. Remove the rear ashtray at the rear of the console to gain access to the cable adjuster.
    2.  
    3. Use a 17mm socket with an extension to turn the nut on the adjuster. Tighten the adjuster a few turns and recheck the adjuster in the car. Continue adjusting until the brakes are firmly applied between the second and eighth notch.
    4.  
    5. Reinstall the rear ashtray.
    6.  

  12.  

Do not attempt to adjust the parking brake only by tightening the cable. The brake shoes must be properly adjusted before the cable is tightened.

  1. Install the wheels. Remove the jackstands and lower the car. Tighten the lug nuts to 80-90 ft. lbs. (108-122 Nm).
  2.  

700 Series
  1. Remove the ashtray and holder from the rear of the handbrake cover.
  2.  
  3. Use a screwdriver and hammer to tap the spring sleeve clear of the adjusting screw.
  4.  
  5. Hold the end of the threaded shaft with a pair of pliers; use an open end wrench to adjust the nut a few turns. Check the brake lever and continue to adjust until brake application is achieved between the second and fifth notches.
  6.  

The system is designed so that the first two notches DO NOT activate the brakes. Don't overtighten the cable.

  1. Check that the spring sleeve is in its original position and reinstall the ashtray and holder.
  2.  

REMOVAL & INSTALLATION



1800, 140 and 160 Series
  1. Apply the parking brake and loosen the rear wheel lugs a few turns.
  2.  
  3. Safely elevate and support the rear of the vehicle and block the front wheels. Remove the rear wheels.
  4.  
  5. Under the center of the car, loosen the locknuts on the adjusting yoke and loosen the brake adjustment. This relieves some of the tension from the cables.
  6.  
  7. Remove the bolt which is the axle for the pivot (pulley) wheel.
  8.  


CAUTION
Although the tension has been lessened, the yoke and cables may spring free suddenly!

  1. Working your way from the front to the rear of each side, remove the rubber boot and retaining nut at the frontmost cable mount and remove the carrier bracket farther back on the frame member.
  2.  
  3. At each rear wheel, compress the spring to relive tension on the arm (Volvo tool 2742 or similar) and remove the lock pin holding the cable to the brake arm. Some cars may have a locking device over the pin; pry it up to gain access.
  4.  
  5. Remove the return spring with the washers. Loosen the retaining nut holding the cable casing to the mount. When both sides are free, remove the cable to the front of the car.
  6.  
  7. Before installing the new cable, properly adjust the shoes at the rear wheels as outlined previously. Install the carriers onto the new cable.
  8.  
  9. Attach the cable to the rear mount and tighten the retaining nut. Do this on each side.
  10.  
  11. Install the spring and washers. Compress the spring and install the lock pin which holds the cable to the brake arm. The lock pin should be lightly oiled before installation.
  12.  
  13. Working towards the front of the car, install the carriers onto the frame member and install the front mount and rubber boot. The boots must be properly seated to keep dirt and water out of the cable casing.
  14.  
  15. Clean and lubricate the pulley wheel and its center pin. Catch the cable on the wheel and install the wheel into the adjusting yoke. Install the center bolt and nut.
  16.  
  17. Adjust the yoke as described previously in this section.
  18.  
  19. Refit the wheels, lower the car to the ground and final tighten the lugs to 80-90 ft. lbs. (108-122 Nm).
  20.  

200 Series

See Figures 5 through 10

  1. Remove the console covering the parking brake lever assembly. Loosen the adjusting screw to relieve tension on the cables.
  2.  



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Fig. Fig. 5: Remove the center console to access the parking brake assembly

The brake cables cross under the car. The cable to the left rear wheel is on the right side of the lever and vice-versa. Know which cable you're changing before proceeding.



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Fig. Fig. 6: The rear of the console houses the pivot point for the parking brake lever-note the cables routed under the carpet

  1. Remove the retaining nut for the cable to be changed; it may be necessary to use a small screwdriver to keep the cable from turning.
  2.  



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Fig. Fig. 7: With the console removed, you can adjust the parking brake (and/or remove the lever, if necessary)



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Fig. Fig. 8: Use a socket to turn the parking brake cable adjusting mechanism

  1. Lift up the front of the rear seat cushion. Move the carpet aside and remove the clamps holding the cable to the floor. Pop the rubber grommet out of the floor pan.
  2.  
  3. Loosen the lugs a few turns; safely elevate and support the rear of the car. Remove the rear wheels.
  4.  
  5. If the vehicle has guard plates over the rear calipers, remove them.
  6.  
  7. Remove the clamp holding the brake line to the rear axle.
  8.  
  9. Remove the caliper mounting bolts and remove the caliper; use a stiff wire to hang the caliper out of the way.
  10.  



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Fig. Fig. 9: Use a stiff wire (such as a coat hanger) to suspend the caliper out of the way and prevent pulling on the brake hose


WARNING
Be careful! The brake line is still attached to the caliper-don't bend it!

  1. Remove the brake disc. The hub is between you and the brake shoes, but you can work around it. Don't attempt to remove the hub.
  2.  
  3. Use a pair of brake spring pliers and remove the retaining spring. Remove the brake shoes; take note of the placement of the adjuster.
  4.  
  5. Press out the lock pin that holds the cable to the lever.
  6.  
  7. Under the car, just ahead of the spring, remove the retaining bolt holding the cable mount to the car. Withdraw the cable and plastic collar. Pull out the complete cable from the center support and the floor pan.
  8.  
  9. Install the new cable by inserting the plastic collar through bracket. Fit the rubber seal at the brake backing plate.
  10.  
  11. Route the cable through the center support and through the hole in the floor panel.
  12.  

Remember that the cables cross each other. The left side cable should go through the hole on the right of the driveshaft and vice versa. Additionally, the cable from the left rear wheel should cross UNDER the right side cable at the center support.

  1. Install the cable into the plastic collar and attach the retaining nut.
  2.  
  3. Lubricate the lock pin and the moving parts of the mechanism at each wheel. Attach the cable and install the lock pin. If the pin has a locking device, bend it back into position.
  4.  
  5. Install the brake shoes with the lower attaching spring. Once in place, install the adjuster and the upper attaching spring.
  6.  
  7. Install the brake disc. Make sure it turns freely without dragging on the brake shoes. Adjust the shoes if needed.
  8.  
  9. Carefully position and secure the brake caliper. Attach the clamp which holds the brake line to the rear axle.
  10.  
  11. Refit the caliper guard if so equipped.
  12.  
  13. Adjust the shoes as outlined in this section.
  14.  
  15. Install the rubber grommet in the floor pan. Make sure it is properly seated.
  16.  
  17. Place the end of the cable into the lever assembly. Install the clamp holding the cable to the floor and replace the carpet and rear seat cushion.
  18.  
  19. At the lever assembly, screw in the nut until the end of the cable projects at least 1 / 4 in. (6mm) beyond the nut. Adjust the cable tension until the crosspiece on the top of the lever is square to the lever (when applied).
  20.  
  21. Adjust the main adjusting screw to get full application of the brakes between two and eight notches on the lever.
  22.  



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Fig. Fig. 10: Adjust the parking brake cable so that the brakes are fully applied between the second and eighth notches

  1. Reinstall the console assembly over the parking brake mechanism. Reinstall the wheel(s) and lower the vehicle.
  2.  

700 Series
SHORT CABLE-RIGHT SIDE
  1. Jack up the rear of the car and safely support it with jackstands.
  2.  
  3. Remove the right rear wheel. Remove the right brake caliper and hang it from the coil spring with a wire. Remove the brake disc. Unhook the rear return spring and remove the brake shoes.
  4.  
  5. Push out the pin holding the cable to the brake lever. Remove the rubber boot from the backing plate and remove the boot from the cable.
  6.  
  7. Remove the spring clip, pin and cable from the back of the differential housing. Remove the cable guide on the differential by removing the top bolt from the housing cover. Remove the cable.
  8.  
  9. Install the boot on the new cable. Check the boots for wear or damage and replace if necessary. Install the cable and position it through the hole in the backing plate. Make sure the boot sits correctly on the backing plate.
  10.  
  11. Smear the contact surfaces of the brake levers with a thin layer of heat-resistance graphite grease. Connect the cable to the lever and install the pin.
  12.  

The arrow stamped on the lever should face upwards and point 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. Connect the cable to the equalizer using the pin and spring clip.
  4.  
  5. Install the brake shoes and rear return spring. Install the brake disc and caliper. Use new bolts, and tighten to to 43 ft. lbs. (58 Nm). Make sure the disc rotates freely. Adjust the parking brake. Install the wheel and lower the car.
  6.  

LONG CABLE-LEFT SIDE
  1. Remove the center console.
  2.  
  3. Loosen the parking brake adjusting screw. Remove the cable lock ring and remove the cable. Pull out the cable from the spring sleeve.
  4.  
  5. Jack up the rear end of the car and safely support it on jackstands. Remove the left rear wheel.
  6.  
  7. Remove the left rear brake caliper and hang it from the coil spring with a piece of wire. Remove the brake disc and rear return spring. Remove the brake shoes.
  8.  
  9. Push out the pin holding the cable to the lever. Remove the rubber boot from the backing plate, and remove the boot from the cable.
  10.  
  11. Pull out the cable from the backing plate and the equalizer on top of the rear axle.
  12.  
  13. Remove the cable clamp on the sub-frame (above the driveshaft) and the cable.
  14.  
  15. Install the new cable through the grommet in the floor; check that the grommet sits correctly. Clamp the cable to the sub-frame.
  16.  
  17. Smear the contact surfaces of the brake levers with a thin layer of heat-resistance graphite grease. Connect the cable to the lever and install the pin.
  18.  

The arrow stamped on the lever should face upwards and point 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. Connect the cable to the equalizer using the pin and spring clip.
  4.  
  5. Install the brake shoes and rear return spring. Install the brake disc and caliper. Use new bolts, and tighten to 43 ft. lbs. (58 Nm). Make sure the disc rotates freely. Adjust the parking brake. Install the wheel and lower the car.
  6.  

 
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