My 1996 850 GLT needs the brake line replaced from the Proportioning valve to the caliper. The nut that holds the line into the caliper is stripped beyond recognition, sothe dealer suggested ordering the new line. Now my problem is removing the old. Has anyone had any experience with this. I can see a small black cover (i guess this covers the valve) but that's all I know about it at this point. I hope it attaches via a nut or something I can unscrew without having to do any cutting. Any help is appreciated!!!!

Thanks - Marty

I'VE LIVED IT. I WAS FORCED TO CUT THE LINE TO REMOVE THE FLARE ON THE BENCH. I USED A TORCH TO CAREFULLY HEAT THE NUT. TRY TO SAVE AS MUCH OF THE OLD BRAKE LINE A S POSSIBLE. THE NEW ONE FROM VOLVO COMES UN BENT. YOU WILL NEED THE OLD ONE AS A GUIDE TO FROM THE NEW ONE.

Oh great. I was hoping the new line was in the correct shape. Looks like I'll become a pipe bender this weekend. Can you tell me how it attaches to the proportioning valve? Never been there before and I've never sen what it looks like. I like to go into this job knowing what I'm up against. If it looks like it's gonna be a bear, I'll bite the bullet and let the dealer do it.

Thanks - Marty

I may be wrong here, but my 93 850 has a junction block located on the rear axle. A few years ago my local inde changed the rear calipers and ran into the same thing. He fabricated a new steel line and replaced the section from the junction block to the caliper on the drives side. Biggest hurdle for a DIY project would be to locate the fittings and have the tools to bend and flare the new pipe.

Yes, mine has that junction box by the axle too and that is called the proportioning valve as my dealer mechanic explained it to me. It is suppose to force the rear brakes to engage before the front to prevent 'nose diving' when the brakes are applied. I just have never seen what this valve looks like and I don't know how the brake line attaches to it.

Thanks - Marty

Maybe 1996 and newer 850's are differant than 93-95, not sure. On 93-95 the proportioning valve is up front by the ABS unit. Just changed mine this summer. Any way since the 96 and newer cars have a differant abs system I can not say for sure where the proportioning valve is. Only know on the old 240's the valves were in the back, but like I said my 93 only had a junction block in back for the brake lines. Standard flare fitting design for the line to the block.

I had a similar issue on my '96 855.

Flare nut was not abused (like on yours), but it was siezed in the caliper and no amount of penetrating oil, or babying, would free it. Realizing that this thing was not going to come out nicely and, realizing that I was going to have to replace the brake line anyway, I cut the line and worked on the caliper and flare nut on a bench. Even with that level of attention, the flare nut broke in the caliper and I ended having to drill it out. That was almost successful except for a few of the flare nut threads that absolutely refused to release themselves from the female threads of the caliper. I did not have a metric tap of that size and nothing I could do would unsieze those bits of metal in the thread.

Ended up having to replace the caliper.

Since you are going to have to replace the brake line anyway, I'd cut the line and work on removing the flare nut on a bench.

BTW, you should always use a flare nut wrench on a flare nut, not an ordinary opened end wrench. But with the brake line cut, you could use a boxed-end wrench which might give you purchase on the abused fitting.

Since I'm replacing the caliper I don't mind cutting the line. Now my question is what does the attachment to the proportioning valve look like? Does it need a special tool to detach or is there another flare nut at this end too?

Thanks - Marty