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    1998 Pontiac Grand Prix 3.8L FI OHV 6cyl

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    1720 S RIDGEWOOD A
    (386) 427-1210

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    Volvo 240/740/760/780/940/960 1990-1998

    Brake Disc (Rotor)

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    REMOVAL & INSTALLATION



    240 Series
    1. Raise and safely support vehicle.
    2.  
    3. remove the front wheel(s).
    4.  
    5. Remove the brake caliper and hang it from the spring with a piece of wire.
    6.  
    7. Remove the two screws securing the disc.
    8.  
    9. Lift the disc off, it may be necessary to tap on the disc with a soft headed hammer.
    10.  

    To install:
    1. Install the new disc, make sure the mating surfaces of the disc and hub are clean and dry.
    2.  
    3. Install the caliper using new mounting bolts.
    4.  
    5. Check the location of the caliper in relation to the disc. Use feeler gauges to check the distance between the disc and the caliper support stubs on both sides. The difference between the two measurements must not exceed 0.001 in. (0.0013mm). Repeat the measurements using the upper and lower support stubs to check if the caliper is mounted parallel to the disc. If the caliper is not correctly aligned, shims can be used to adjust the caliper's position.
    6.  
    7. Install the brake pads and make sure that the disc can rotate freely between the pads.
    8.  
    9. Install the disc securing screws.
    10.  
    11. Install the wheels.
    12.  
    13. Check brake pedal function before driving vehicle.
    14.  

    700 Series, 900 Series, S90 and V90 Models
    1. Raise and safely support the vehicle.
    2.  
    3. Remove the wheels.
    4.  
    5. Remove the caliper and brake pads.
    6.  
    7. Hang the caliper from the spring, to avoid damaging the brake hose.
    8.  
    9. Remove the wheel pin guide and brake disc.
    10.  
    11. Clean the hub flange, remove the corrosion with a scraper and or wire brush.
    12.  
    13. Clean the ABS pick-up and toothed wheel using a soft brush.
    14.  

    To install:
    1. Ensure that the mating surfaces on the hub and disc are clean.
    2.  
    3. Insert guide pin and tighten to 6 ft. lbs. (8 Nm). Reinstall the ring gauge and cross tighten the lug nuts to 63 ft. lbs. (85 Nm).
    4.  
    5. Measure disc run-out. Measure on the disc surface 0.60 in. (15mm) in from the edge. Maximum run-out is 0.0023 in. (0.060mm). Remove the measuring equipment.
    6.  
    7. Install the caliper carrier using new mounting bolts, then install the caliper and brake pads.
    8.  
    9. Operate the brake pedal several times and check the fluid level.
    10.  
    11. Install the wheels.
    12.  
    13. Check brake function before driving vehicle. Limit hard braking whenever possible during the 500 miles (800 km) after pad replacement.
    14.  

    850, S70, C70 and V70 Series

    See Figures 1 and 2

    1. Raise and safely support the vehicle.
    2.  
    3. Remove the wheels.
    4.  
    5. Remove the brake caliper and brake pads.
    6.  
    7. Remove the carrier.
    8.  
    9. Remove the guide pin bolt.
    10.  
    11. Remove the rotor and clean the hug flange of all corrosion and dirt.
    12.  
    13. Check the hub run-out by mounting gauge ring (Volvo tool 5419 from tool kit 5418) or equivalent.
    14.  
    15. Install the dial indicator on the spindle (using the caliper bracket bolt holes). Place the probe end to the gauge ring.
    16.  
    17. Turn hub slowly and identify the highest point. If the run-out exceeds 0.0007 in. (0.020mm), the hub must be replaced.
    18.  
    19. Remove the measuring equipment.
    20.  

    To install:
    1. Install the brake rotor.
    2.  
    3. Tighten the guide pin bolt to 72 inch lbs. (8 Nm).
    4.  
    5. Install the caliper carrier using new bolts.
    6.  
    7. Install the brake caliper and brake pads.
    8.  
    9. Depress the brake pedal several times and check the brake fluid reservoir.
    10.  
    11. Install the wheels.
    12.  
    13. Check the brake function before driving vehicle.
    14.  



    Click image to see an enlarged view

    Fig. Fig. 1: Remove the wheel guide pin bolt ...



    Click image to see an enlarged view

    Fig. Fig. 2: ... and remove the brake disc from the hub

    INSPECTION



    Inspect the brake rotor for scoring and wear; minor scoring or disc pad lining build-up does not require rotor machining or replacement. If heavy scoring, cracks or other damage is evident, replace or have the rotor machined, as necessary.

    Glaze on the rotor can be removed by hand-sanding it with medium grit garnet paper or aluminum oxide sandpaper.

    The minimum thickness of each brake rotor is indicated on the rotor itself. Do not utilize a rotor which is worn below the minimum allowable thickness. If rotor damage cannot be corrected by grinding to these minimums, the rotor must be replaced.

    Rotor lateral run-out must not be more than 0.001 in. (0.035mm).

     
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