Well, I've been working on the driver's emergency brake cable. 89 240 project wagon. Bought new emerg brake shoes, the hardware kit and a new (Gemo) emergency brake cable for $19 from Groton.

Cleaned the connector mechanism at the brake end, installed new hardware and shoes, with new springs - easy part should be the adjustment. The threaded cable end would not go into the aluminum plate that provides adjustment. What's going on here? Kept pushing it and nothing - a simple threaded end through a hole - how difficult can that be?

Looked at the old cable - the threaded end is tapered square to fit through the adjusment end holder that's square(two of these - one for each cable). Of course, the old Volvo orignal one went in and out easy. Turns out the aftermarket cable has a tapering on the metal sleeve that 5 sided and not just four. So it got stuck in the adjustment holder. I got so mad at this thing, I took out both seats for easier access (was going to change them with another set I have anyhow).

To use the new cable I had to drill out a bit of material out of the adjustment holder. Soft aluminium. Think first before drilling. Big mistake - took out too much and the cable flops around in it instead of remaining tight so when you lift the brake lever it will not go back to release properly. Ended up jamming a bit of metal in the aluminum housing (adjustment thing) and got the cable to stay in place. But that messes up the adjustment nut and its function.

The problem I have now is the passenger brake cable is perfect - pull up and the wheel locks, down and it spins freely by hand with a slight touch. The drivers side still does not release as well - the wheel will spin, but with more effort.

This brake cable has been a bigger pain in the ass that doing the entire rear main seal - plus I tore the carpet getting the darn old one out. The question is: do the emergency brakes free up with wear on the pads or will this drag a bit in contrast to the other side. Debating about getting a new adjustment flange for the driver's side, since I have the seats out.

Plus, this whole mess started with an aftermarket part that should fit correctly - never fails. And, I had a supplier give me rear calipers that were for a 140 last week instead of a 240 - not doing well on parts recently. Thinking about buying Volvo number 50 this week - maybe I should quit for a bit! LOL

Bob Weber
49 Volvos since 1979
Hamilton, Ohio 45013