I would say this a longshot but I just put an S40 on the road and it had a braking issue. What I found was that each pad fit too tight in the caliper frame. One set of pads were clearly marked Volvo and the other set was not. All four wheels required removal of the pads and filing the backing plate edges to fit the frames properly.
This my first FWD Volvo (have owned-bought-sold many, many, many RWD Volvos -- as well as many other brand FWD cars) and it fell into my lap -- a 2002 model with only 24,750 miles. I thought it very strange that with so few miles at least one set of pads would have had to be replaced - and the Volvo pads were so thick they might have been new as well. My conclusion was that the pads were not manufactured correctly. -- Dave
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