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After finding the junction block leaking at the brake failure warning light switch and an earlier post on Brickboard, I was set to try to rebuild my junction block.
I was able to order the O-rings at Volvo for $1.65 each (two are needed). The part number is 1330797-0.
I think the block could be rebuilt on the car however you will not be able to get a good look at the bore to check for rust or pits. Pull the block, remove both end plugs to disassemble and clean it up. If there is any question as to the condition of the bore, STOP. Pitch the old block in the trash and go to Volvo for a new one. If the block bore is good (as it was on mine) reassemble with the new O-rings and put it on the car.
Time to bleed the system. I picked up a Motive Products Power Bleeder from FCP that made the job fast and I was able to flush the entire brake system at the same time. After bleeding, hold the brake pedal down for a minute or so and then check for leaks at the switch and the block lines.
This turned out to be a 2 hour job, however if you are not comfortable with removing brake components take it to a shop.
Happy Bricking
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1984-244 GL with 201K, 1984-244 GL with 270K (parts), 1985-244 DL with 238K, 1985 DL with 280K, 67 Mustang with 250K and 62 F- 250 4x4 with 71K
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