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need insight into rear caliper replacement - tool clearance 200 1988

Doing my preliminary work on what I need to replace my rear wheel brake calipers.
They are ATE though I do not see that that matters.

I am not finding clearance to the bolts/fittings.

1) Rear Caliper Mounting 17mm Bolts:
- There is no clearance between the suspension spring and the bolt for a standard socket AND ratchet. It appears there is little space from the end of the ratchet head to the top of the bolt so grinding off a socket does not look to help me (?) Is this a 'special shallow' socket job?
- I think I can, with some jacking of the body, get to the caliper mounting bolts through the suspension spring using an extension. Not fond of the idea of putting a lot of torque on the bolts and not have good control of the axis of rotation.
- My 17mm socket feels much tighter than my 17mm box wrench. Should I be looking for a new box wrench? How would I torque the bolts when putting them on?

2) Brake Line Fitting:
- The brake line fitting on the caliper, in relation to the suspension spring, is such that there is no angle that my 11mm brake line wrench will slip over the hex. If it did there is next to no room to rotate it.
- I do need to have the caliper attached to loosen that fitting don't I?

Am I really supposed to remove the suspension?
Any other tips and/or warnings?
--------------------
1988 244 DL; B230F; LH-2.2; Manual 5-speed (M47)








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remanufactured rear caliper pistons not to spec - is there a hack? 200 1988

I have received a NuGeon reman rear brake caliper but the pistons are not oriented per the Green Book. They are 180+ degrees out.

The manual indicates the piston is to be positioned so the recessed portion of the piston bearing surface is to the bottom of the caliper and turned to slope 20 degrees, from front to back of vehicle, off the bottom surface of the caliper.

This is indicated to be done "to avoid brake squeal".

I do not have the tool to turn the installed piston.

Is there a hack way to do this?
--
1988 244 DL; B230F; LH-2.2; Manual 5-speed (M47)








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remanufactured rear caliper pistons not to spec - is there a hack? 200 1988

a) A proper expanding threaded block with inside jaws to grab the rough inside of the piston is obviously the proper tool for the job. They're not grossly expensive, but I hear you about trying it some other way. There's also a threaded block shaped disk piston tool that is meant for aligning and inserting pistons. They can be relatively inexpensive, like $10-$15. I haven't used one so I can't attest to how well they might work for changing piston orientation and fitting into Volvo calipers, especially the rears.

b) You spent good money on these reman calipers. Is there not some way you can return them in exchange for properly oriented rebuilds? The minute you goof with them you risk damage and a voided warranty. If nothing else, you are owed at least a partial refund. This is by far the best approach to protect your investment.

c) Attempt to turn the pistons using something else wedged into the recess. Brake fluid from behind and in front for lubrication is generally required to make this doable. Try wedging in various sharp edged tools, my favourite is the single jaw of a large slip joint plier. No matter what, you must not scratch or damage the outer surface sides of the piston and do try to avoid significant damage to the piston face contact edge.

d) Pop the pistons out all the way past the seals with compressed air and re-insert them in the proper orientation using something like a centred C-clamp and plenty of lubrication (brake fluid). In experienced hands this isn't that hard to do, but you do risk tearing the seals if you can't keep the piston centred and perpendicular. If you've never done this before, I wouldn't be practicing on brand new calipers.

e) I am not at all recommending this for new calipers, but would certainly attempt it as a last resort on old calipers and have done so in the past for minor adjustment. Extend the pistons as far as you can then grab the piston outer surfaces with a non-marring grip, like the padded jaws of a carepenter's F-clamp or a C-clamp or welder's Vice-Grips with the piston well wrapped in protective tape. When extending the pistons, you don't want to break the seal if you can help it, which generally requires mounting them on the car and sticking something like the backing plate of an old disk pad, or equivalent thickness, in as a spacer then using compressed air to blow the pistons out against them, then removing the calipers to play with them on the bench. You will also need to carefully pop out the dust seals for access, just don't accidentally puncture them, which is so easy to do if you slip.

f) If you can't/won't return them, then maybe try living with them the way they are before inadvertantly damaging them. I wouldn't mind betting the anti-squeal properties of the stepped design are not grossly affected by the pistons being 180 deg out of proper orientation. In case you haven't noticed, lightly applied brakes can squeal plenty in the reverse or the forward direction.
--
Dave -still with 940's, prev 740/240/140/120 You'd think I'd have learned by now








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remanufactured rear caliper pistons not to spec - is there a hack? 200 1988

Dave,

I get your point on wanting the properly remanufactured caliper.

- Called NuGeon and the tech there was unaware of the piston orientation.
-- NuGeon also reported the one I had in my hand was the only one showing in inventory ... on the continent.

- Since parts suppliers are not covering shipping and there was no hope a second caliper would be better than the first it was a waste of money to send it back.
-- In fact I was surprised FedEx beat out USPS on shipping the core back by almost 50%. But then USPS can not be depended on to get mail to my address.

- I did check with the local dealership and auto parts stores to see about availability of tools. The parts counter at the dealership was not at all hopeful the tool existed. The brake tool set at the auto parts store did not have the specialty tool.

In the end I just put it in with fingers crossed.
--
1988 244 DL; B230F; LH-2.2; Manual 5-speed (M47)








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remanufactured rear caliper pistons not to spec - is there a hack? 200 1988

Like Dave suggested, I stuck the jaw of a small pair of pliers inside the piston to grab it.



Then, later, I cobbled up (hacked) a "tool" with a rubber foot which fit snugly inside the piston.



20 years ago my daughter was driving a 240 to school. The rear brakes squealed until I clocked the notch.
--
Art Benstein near Baltimore

"A gentleman is someone who can play the accordion, but doesn't." -as retold by Monte Leister








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need insight into rear caliper replacement - tool clearance 200 1988

tbb2 wrote--"- I think I can, with some jacking of the body, get to the caliper mounting bolts through the suspension spring using an extension." That's exactly how to do it. Use a 3/8 drive extension and socket with a 1/2 breaker bar or ratchet and 1/2 to 3/8 adapter. Support the car under the jack points so the springs are stretched. I've never had any problem loosening the brake line with a line wrench--small bites and flip the wrench each time to go a bit more ---or remove the caliper bolts first and the clamp that holds the brake line to the axle tube. You can then pull the caliper back a bit (put a box under it so it doesn't drop down) and you'll have enough clearance. Torquing the caliper bolts is not really necessary. Make them as tight as you can with a 3/8ths drive ratchet or 10 inch long box wrench. -- Dave








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need insight into rear caliper replacement - tool clearance 200 1988

On re-reading my post I'll add this--if you can't get the socket squarely on the bolt head because the gap in the spring is off by a little -- use a "wobble" type extension. -- Dave








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need insight into rear caliper replacement - tool clearance 200 1988

That is what happened.

I jacked the car up to get a shot into the bolts.

I did have to remove the caliper to get access to the brake line fastener.
--
1988 244 DL; B230F; LH-2.2; Manual 5-speed (M47)








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need insight into rear caliper replacement - tool clearance 200 1988

Try jacking the axle up a little or pull it down a bit to move the gap in the springs. Never had a problem getting at the caliper bolts with a 1/2" extension through the springs on an 18" breaker bar, 32" breaker is a breeze. Factory used loctite so first time off is the hardest.
--
Dave -still with 940's, prev 740/240/140/120 You'd think I'd have learned by now








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need insight into rear caliper replacement - tool clearance 200 1988

Do you have a position on the repair manual notes calling for replacing the caliper bolts?
--
1988 244 DL; B230F; LH-2.2; Manual 5-speed (M47)








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need insight into rear caliper replacement - tool clearance 200 1988

Caliper bolts are torqued a bit close to yield using loctite, hence the recommended bolt replacement in case they were ever over-tightened. Few people or shops bother to replace the bolts. Few people bother with the recommended loctite, either.

I've never heard of a caliper coming loose if the bolts were half properly tightened. Still, I recommend properly torquing them and I always do. Main thing is not to get carried away and overtorque a previously used bolt closer to the failure point.

Volvo torque specs should be something like:

240 Front caliper bolts 100 Nm, 74 ft-lbs, 890 in-lbs
Rear caliper bolts 60 Nm, 46 ft-lbs, 535 in-lbs

700/900 Front caliper bolts 110 Nm, 78 ft-lbs, 930 in-lbs
Rear caliper bolts 60 Nm, 46 ft-lbs, 535 in-lbs
Front caliper guide pin bolts 30 Nm, 24 ft-lbs, 270 in-lbs

Careful with bleeder nipples. Huge pain if they break off. If the bleeders haven't been opened in a long while then soak overnight in penetrating oil. Avoid using a 3/8" ratchet, even a 1/4" ratchet, much better off by hand with a box end wrench or flare wrench where you can better sense force and movement. To break the thread seal, if it won't break counter-clockwise then try a little jerk clockwise. Do this with increasing force until it cracks free. Avoid rocking the wrench quickly back and forth as it increases metal fatigue. I often find a gentle tap with a hammer to the wrench to break the thread seal works well if you're careful.
--
Dave -still with 940's, prev 740/240/140/120 You'd think I'd have learned by now








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need insight into rear caliper replacement - tool clearance 200 1988

I've never replaced caliper bolts -- and never have had a caliper fall off. :-) Dave







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