Hi,

I have a 1994 Volvo 940 wagon w/ turbo. Runs nice but I just encountered a problem.

I took my car in for a yearly inspection. When testing my emergency brake, the "mechanic" yanked the brake arm like he was curling weights and consequently snapped the cable mounting on the rear axle. I wasn't too pleased but what can you do?

Subsequently I had another cable bracket MIG welded onto the rear axle. After also replacing the parking brake shoes the rotor now won't fit over the new shoes and mount flush with the wheel hub. I can force it in but the rotor then doesn't sit squarely on the wheel and so the brake calipers don't line up w/ the bolt holes because the rotor isn't square to the hub, the pads are slightly askew and the calipers won't line up. The new brake shoes seem to be just too big. Checked to be sure they're the right part and yes they are.

Finally I got the brilliant idea to use one new shoe in combination with one old shoe. The rotor fit this way so I tightened it all up and thought it was all good BUT tbe damn parking brake while better still doesn't hold - Surprise! It seemed like a good idea at the time but it WAS NOT.

So now I'll pull it all out and try it again using all new pads. Anticipating the same problem of not being able to fit the rotor over the new pads does ANYBODY have any experience w/ this and/or suggestions?

BTW - this model does NOT have an adjusting nut on the parking brake shoes. There's a metal bracket that holds the "other" shoe end a fixed distance apart. I'm gonna visit the boneyard to try and find an adjusting nut for the shoes and hope that may solve the problem.

The damn rotor just doesn't fit. (new rotors BTW)

as always any help is greatly appreciated

Well, if he could break it by pulling on the handle, it wasn't "long for this world" and wouldn't have helped much in a real emergency, I guess...

My guess is that the adjuster bolt that you can access by removing the rear seat ashtray and the panel behind it is too tight, and not allowing enough slack to get the rotors back on. It is nylon and about 17mm if memory serves...

The other thing to check is for seized actuator levers where the cable connects at the rear axle. They should pivot on two axes, not just one. Pull them out, lubricate them and get them moving right, then coat with a smear of antiseize.

I always order new springs and keeper spring kits for parking brake rebuilds. FCPgroton.com has good prices on the components.

Use antiseize on the hubs when reinstalling the rotors and you will thank yourself when they have to come off again.

Good luck!
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Herb Goltz, Aurora, Ontario, Canada '92 245 140K mi, '92 945t 210K mi

I do not have much knowledge on the parking brake but this may help. There is a parking brake adjusting screw, which part of the normal maintenance. You may get some needed slack from it. You can access by removing the center console.

I had a similar frustration once and it turned out that I had put the springs on the wrong sides. be sure that you put the short spring on the fwd point, and that you have the short metal bar that holds the shoes apart, in the right spot.