Hello All,

I have 2 1996 850 GLT Wagons, with 5 speed manuals, which are non-turbo. I also have a 1999 XC. I plan, God willing to hold onto these cars for ever. I'm going in the right direction already, as one 850 has nearly 260,000 (purchased new - my wife drives) and the other almost 200,000 (mine - purchased used when it was 3 years old with 50,000). The XC almost has 90,000 (my wife and I purchased it used for my late father-in-law when it had 12,000).

With this long term ownership in mind, I want to learn how to do a complete brake job on these cars, including replacing the rotors if required, and how to properly bleed the brakes (there is I believe a difference in procedure for cars with clutches vs. automatics). Also, is there a difference in doing a brake job on 850 vs a XC?

I've looked at the Haynes manual, but feel there are gaps in the details and photos. I'm looking for a source that would have extensive details combined with photos of step by step procedure. Sort of a "Volvo Brake Jobs for Dummmies" approach. I have no shame in saying that, and hope no one will hold it against me. I recognize there is an important issue of safety here, especially since my wife and 3 small children ride around in these cars. I want to save money, but not put them in jeopardy.

Also, I would appreciate it, if any one could show me to a source (photographs again most likely) that would show me when brake pads and rotors are worn and have to be replaced. I do check the pads on the cars when ever I take the wheels off, and there seems to be sufficient thickness to them. I ask my independent garage to check the wear on the brakes when ever any of the cars are in for service. When garage owner tells me I have less than 10,000 miles wear (I believe him), I tell him to replace them because mileage, especially on my wife's car is racked up quickly, and she isn't afraid to stomp on the brake. She goes through pads much faster than I do. Plus I figure, pads are cheaper than rotors that get destroyed when the metal rivets on the pads come in contact with them.

Any way, sorry for the long message. I appreciate any replies. Let me close my message by wish you all a Happy New Year!

Hugh

Hi,
few additional points to consider with over 10y old 850 front brakes:
-if the front caliber piston dust boot is no more correctly positioned in its place then consider installing factory renewed front calibers, new rotors and pads at the same time
-if the rubber hose has never been renewed or has cracks then replace the old one
-allways do the same on left/right

I had to do this on my 850 -94 with 260kkm as the left front cylinder was sticky. Only point with difficulties was the CuNi pipe / rubber hose joint, which was difficult to open as the nut material is soft and I had no suitable box spanner available. Had to renew finally the CuNi pipe as well (10€ cost).

Don't pospond this too much as you will enjoy the renewed responsive brakes.
Br Tapsa

Br. Tapsa,

Thanks. You're response shows how the ownership of Volvo 850s is global.

Hugh

Hugh, sign up on this board. Jarrod does not sell your info!!

Take a look at http://volvospeed.com/maintenance.shtml
They have lots of pics.

The brake pads and procedures are different between your 850 and XC, but not a lot. The slide pins on the 850 require a 7mm allen wrench and the XC wants an 8mm alen wrench. The XC rear brakes are similar to the 850 front wheels, as far as procedure goes.

Front rotors are a piece of cake! The rear drum rotors are a pain if the brake cable is not loosened up first.

Get a some brake grease at your local auto parts store, my sells it in little packets. Each packet is good for 8-12 brakes.

I also never trusted my self to do brakes, until I found the Brickboard. Now, it is something that is so easy, you wonder why the shops charge so much!!

I still leave flushing brake fluid to the shops, only because it is fairly cheap for them to do. With a manual shift you will need a pressure bleeder.

Klaus
--
The 164 has a new home, all I am left with are a 95 854T and a 98 V70R :)

Klaus gave good advice. Brakes really aren't that hard once you learn them.

The best thing I've ever done brake-related was to buy an extra reservoir cap, drill a hole in it, and silicone a bike tire valve in it. Instant pressure bleeder! I made it for my 240's years ago, but was happy to learn that the 850 threading is the same! Now to bleed, all I need to do is hook up a bike pump and pump the thing while making sure the reservoir does not run out of fluid. Just used it on my 850 with excellent results. I would always suggest against the pedal method of bleeding--there's just too much potential for messing up master cylinder bores.

The first time I did brakes on a 240, I had a haynes manual right beside me the entire time. the biggest pain was that the copper brakes lines were jammed and had to be cut off. Now I have an 11mm snap-on flare nut wrench and all is well in that department. Anyways, that brake job included front calipers and rotors as well as bleeding the entire system, and the haynes manual was more than sufficient for my (then) very limited auto knowledge.

Good luck and if you have questions, ask the brickboard!

Nate

--
1997 850, 1979 242GT, 1990 740GL

Here's a few more URL's to cross reference the pictures and get a better look at things:
http://www.freewebs.com/dacvolvo/brakediscsandpads.htm

http://www.matthewsvolvosite.com/chat/phpBB2/viewtopic.php?t=6774

http://www.matthewsvolvosite.com/chat/phpBB2/viewtopic.php?p=26225
essential for removing rear disk under adjusting the parking brake shoes

Haynes guide

http://volvospeed.com/Repair/jackingpoints.php
http://volvospeed.com/850fbrake1.php
http://volvospeed.com/850rbrake1.php

http://au.geocities.com/ozbrick850/brakes.html

http://www.volvoclub.org.uk/tech/service/850/BrakeSystem.pdf

I agree with all others who say easy once you've done it, and a big money saver to DIY. Also, bought parts from FCP Groton and gets to me next day UPS.
Have fun,

'97 855na 176K, Mobil 1, K&N, various IPD's and eBay's

Lilhelphere, Uggthat and Klaus,

I thank all three of you for your responses. I'm saving the information you gave me, so when I need to do a brake job on one of my Volvos, I'll be prepared.

The Best to you All!


Hugh