Volvo Truck 2003-05

Brake Caliper

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Removal & Installation



  1. Remove the wheel.
  2.  
  3. If the caliper is being replaced:
    1. Secure the pedal in the depressed position. Use a pedal jack.
    2.  
    3. Clean the brake caliper thoroughly.
    4.  
    5. Remove the protective cap from the bleed nipple.
    6.  
    7. Install a plastic hose on the nipple.
    8.  
    9. Open the bleed nipple. Collect the brake fluid in a container. Shut the bleed nipple.
    10.  
    11. Slacken the off brake hose approximately half a turn.
    12.  

  4.  
  5. Remove the retaining spring carefully so as not to deform it.
  6.  
  7. Remove:

    The protective caps from the two locating pins
     
    The locating pins
     
    The brake caliper from the holder
     
    The brake pads.
     

  8.  
  9. Unscrew the brake caliper from the brake hose.
  10.  
  11. Drain the remaining brake fluid.
  12.  
  13. Insert the brake caliper on brake hose (Do not tighten)

    Click image to see an enlarged view

    Fig. Front brake exploded view

    Front brake exploded view
  14.  

To install:

  1. Install:

    brake pads
     
    brake caliper in the holder.
     

  2.  
  3. Lubricate the locating pins using grease caliper grease.
  4.  
  5. Insert the locating pins into the rubber sleeves. The pins should slide into the sleeves easily.
  6.  
  7. Tighten the locating pins to 20 ft. lbs. (28 Nm).
  8.  
  9. Install the protective caps.
  10.  
  11. Install the securing spring.
  12.  
  13. Tighten the brake hose to 13 ft. lbs. (18 Nm).
    NOTE
    The brake hose must not be twisted.

  14.  
  15. Fill and bleed the brake system.
  16.  

 
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