Mechanics

BRAKE PADS AND ROTORS

1999 Volvo S80

Brakes problem
1999 Volvo S80 6 cyl Front Wheel Drive Automatic 70000 miles

I need step-by-step instructions on how to change front brake pads and rotors
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SteveP82
October 10, 2009.



FRONT DISC BRAKE PADS Removal 1. Raise and support vehicle. Remove wheel to be serviced. 2. Remove the securing spring (3) carefully so that it does not deform. See Fig. 22 . 3. Remove the protective caps (1) from the two locating pins (2). See Fig. 22 . 4. Remove the locating pins by using a 7 mm hex socket. 5. Remove the brake caliper from the holder. Hang brake caliper from a safety wire from the front spring so as not to damage brake hose. Remove the brake pads. Fig. 21: Exploded View Of Front Brake System Courtesy of VOLVO CARS OF NORTH AMERICA. Fig. 22: Removing Securing Spring & Locating Pins - Front Brakes Courtesy of VOLVO CARS OF NORTH AMERICA. Inspection  Clean and check brake pad mating surfaces in the brake caliper and caliper holder.  Check piston dust boot. Replace dust boot if it is damaged.  Check the brake disc friction surfaces. If the brake disc displays signs of out-of-true, check its lateral run-out. See MEASURING LATERAL RUN-OUT under INSPECTION.  Replace the disc if it displays signs of heavy wear, variable thickness or similar.  Measure brake disc for minimum thickness and check against specifications. See DISC BRAKE SPECIFICATIONS . Installation 1. Press the piston back into cylinder on brake caliper. Check that the dust cover is correctly positioned. 2. Install new brake pads. See Fig. 23 . 3. Install the brake caliper. NOTE: For exploded view of brake components, see Fig. 21 . NOTE: See DISC BRAKE SPECIFICATIONS for minimum thickness for replacing brake pads. NOTE: Do not depress the brake pedal while the brake pads are removed. NOTE: If dust boot is damaged, dirt may have penetrated the cylinder, therefore the brake caliper must be reconditioned.
4. Check the rubber sleeves of the locating pins. Replace if necessary. 5. Lubricate the locating pins (2) with grease(part no. 1161325-4, or equivalent). Insert the locating pins into the rubber sleeves. The pins should slide into the sleeves easily. See Fig. 22 . 6. Tighten locating pins to specification. See TORQUE SPECIFICATIONS . Install the protective caps (1). See Fig. 22 . 7. Install the retaining spring (3). See Fig. 22 . 8. Depress the brake pedal a few times. Check the level of the brake fluid reservoir. Top off if necessary. 9. Install wheels and tighten to specification. See TORQUE SPECIFICATIONS . Fig. 23: Installing Front Brake Pads Courtesy of VOLVO CARS OF NORTH AMERICA. FRONT BRAKE CALIPER Removal 1. Raise and support vehicle. Remove wheel to be serviced. 2. Secure pedal in depressed position using a pedal jack. 3. Clean brake caliper thoroughly. 4. Remove protective cap from bleed nipple. 5. Install a plastic hose on the nipple. 6. Open bleed nipple. Collect brake fluid in a container and shut the bleed nipple. 7. Loosen the brake hose (4) from the brake caliper half a turn. See Fig. 24 . 8. Remove the securing spring (3) carefully so that it does not deform. See Fig. 24 . 9. Remove the protective caps (1) from the two locating pins (2). See Fig. 24 . 10. Remove the locating pins by using a 7 mm hex socket. 11. Remove the brake caliper from the holder. 12. Remove the brake hose from the brake caliper. Drain the remaining brake fluid. 13. Remove the brake pads. Fig. 24: Removing Front Brake Calipers Courtesy of VOLVO CARS OF NORTH AMERICA. Installation 1. Install the brake hose (4) in the brake caliper. Do not tighten the hose yet. See Fig. 24 . NOTE: For additional information, see Fig. 21 . NOTE: Do not depress the brake pedal while the brake pads are removed. 2. Install the brake pads. 3. Install the brake caliper. 4. Check the rubber sleeves of the locating pins. Replace if necessary. 5. Lubricate the locating pins using grease (part no. 1161325-4, or equivalent) and insert the locating pins into the rubber sleeves. The pins should slide into the sleeves easily. Tighten them to specification. See TORQUE SPECIFICATIONS . 6. Install the protective caps and the securing spring (3). See Fig. 24 . 7. Tighten the brake hose in the caliper to specification. See TORQUE SPECIFICATIONS . 8. Remove pedal jack from brake pedal. Fill brake fluid reservoir and bleed the brake system. See BLEEDING . 9. Install wheels and tighten to specification. See TORQUE SPECIFICATIONS . FRONT BRAKE DISC Removal 1. Raise and support vehicle. Remove the securing spring and locating pins. 2. Remove the brake caliper and brake pads. See FRONT DISC BRAKE PADS . 3. Remove and discard both mounting screw (4) for the caliper holder. See Fig. 25 . 4. Remove the front brake caliper holder (mounting bracket). 5. Remove the locating pin (5) and the brake disc. See Fig. 25 . Fig. 25: Removing Front Brake Disc Courtesy of VOLVO CARS OF NORTH AMERICA. Inspection  Clean the hub flange before installing the new brake disc.  Check the hub. If it is damaged, measure the lateral run-out. See MEASURING LATERAL RUN-OUT under INSPECTION. Installation NOTE: Ensure that the brake hose is not twisted. If necessary adjust the hose at the other end (brake pipe end). If the brake hose is twisted it may rub against the tire, rim or wheel arc. This could cause the brakes to fail. NOTE: For additional information, see Fig. 21 . NOTE: Manufacturer recommends replacing caliper holder screws if loosened or removed. 1. Install the new brake disc. Tighten the locating pin (5) to specification. See TORQUE SPECIFICATIONS . 2. Install the caliper holder. Use NEW mounting screw (4) and tighten to specification. See TORQUE SPECIFICATIONS . 3. Install the brake pads and brake caliper. 4. Install the locating pins in the brake caliper and tighten to specification. See TORQUE SPECIFICATIONS . 5. Install wheels and tighten to specification. See TORQUE SPECIFICATIONS .
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Merlin2021
Oct 10, 2009.