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 brake caliper and brake pads. See the Pad R&I procedure.
  6.  
  7. Unscrew the brake caliper from the brake hose.
  8.  
  9. Drain the remaining brake fluid.
  10.  


    Click image to see an enlarged view

    Fig. Rear brake exploded view

    Rear brake exploded view

To install:

  1. Insert the brake caliper on the hose and hand tighten.
  2.  
  3. Clean and install the brake pads and brake calipers.
  4.  
  5. Tighten the brake hose to 13 ft. lbs. (18 Nm).
  6.  


NOTE
The brake hose must not be twisted.

  1. Fill and bleed the brake system.
  2.  
  3. Depress the brake pedal a few times. Check the level of the brake fluid reservoir.
  4.  

  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 brake caliper and brake pads. See Brake Pads removal and installation.
  6.  
  7. Unscrew the brake caliper from the brake hose.
  8.  
  9. Drain the remaining brake fluid.

    Click image to see an enlarged view

    Fig. Rear brake exploded view

    Rear brake exploded view
  10.  

To install:

  1. Insert the brake caliper on the hose and hand tighten.
  2.  
  3. Clean and install the brake pads and brake calipers.
  4.  
  5. Tighten the locating pins to 20 ft. lbs. (28 Nm) plus 60°.
  6.  
  7. Tighten the brake hose to 13 ft. lbs. (18 Nm).
    NOTE
    The brake hose must not be twisted.

  8.  
  9. Fill and bleed the brake system.
  10.  
  11. Depress the brake pedal a few times. Check the level of the brake fluid reservoir.
  12.  

 
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