940 GLE 1992 60K miles mint shape

I've recently noticed a slight grinding sound (not squeeling loudly but crunching quietly) that quietly comes from the front brakes, not sure if both sides or not... The pads and rotors were replaced 2 years / 15K miles ago. I have been periodically looking at the thickness of the pads and have found that they miraculously seem to be lasting forever.

Last night I decided to remove the passenger side wheel and take a peek. The pads (both of them) seem to still be at least 75% thick. The rotors do not appear to have any major wear or surface dents on them.

The grinding sound is on/off depending on the day. Up here in Montreal Canada, we have snow and salt, so I was thinking that maybe dirt/salt is causing this... but I have never really experienced that before. The calipers do not feel sticky at all.

Any suggestions? Of course, replacing the rotors and pads will solve this issue, but why if they look smooth and thick?

Note the brake pedal does not really vibrate significantly at all. Braking seems strong and even on both sides (as tested in snow with ABS). The grinding, or crunching sound is often heard/felt just before the car reaches the stop, not at high speed.

What do I do?

Thanks,
Greg Mustang

'92 940 GLE 16V B234F 60K miles
'89 240 DL B230 130K miles (just entered Volvo High Mileage Club)

I've seen this on quite a few 940's. Usually after replacing pads only on cars with good front rotors. Damned if we could ever figure out WHY it did it, but new rotors do fix it. Yes, it's annoying. No, it never seems to hurt anything. It apparently has to do with a small rust ridge forming at the inner edge of the rotor, now hittign the inner edge of the pad. Two things you can do: replace the rotors (no fun, big $$$) or remove each front brake pad in turn, and grind off the inner bottom edge to a taper. This should clear the ridge and stop the noise. There's no asbestos in new brakes, but this will make a bit of dust, so wear breathing protection. I recommend shaping the pads on a bench grinder.
You're certainly not the first person to experience this particular annoyance.
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Rob Bareiss, New London CT ::: 86 244DL, 87 244DL, 88 744GLE, 91 244: 808K total

Sand embedded in pads? If it occurs after parking overnight, it could be rust on the rotors, but this will wear off immediately.

I have exactly the same thing. No sound during occasional breaking and then resuming speed, but a slight grinding noise just before I come to a stop. I've only had this since I got new snow tires put on, so I'm assuming it's something to do with the new tread patterns? Like you, my pads and rotors are healthy.

Same problem just started happening on my 95' 960. Brake pads are at approx 40% in front. I think my rotors and pads might be glazed. Replacing pads as preventative measure.
I'll keep you posted as to the results.