1986 1993 Volvo 240 Front Brake Pads Replacement 1986 1987 1988 1989 1990 1991 1992 1993 Repair Guide

Difficulty

Moderate

Steps

Time Required

                          1 hour

Sections

Front Wheels
1 step
Front Brake Pads
5 steps

Flags

Back1986-1993 Volvo 240
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Introduction

What you need

Step 1

              Front Wheels

Jack up the front of the car and place it on jack stands.
Never work on or underneath a car that is only supported by a jack. The jack may slip or fail, resulting in serious injury or even death.
Use an impact wrench or lug wrench to remove the five 19 mm lug nuts from the front wheel.
The wheel lug nuts should be torqued to 85 ft-lbs when the wheels are put back on the car.
Pull the front wheel off the wheel lugs and set it aside.

Jack up the front of the car and place it on jack stands.

Never work on or underneath a car that is only supported by a jack. The jack may slip or fail, resulting in serious injury or even death.

Use an impact wrench or lug wrench to remove the five 19 mm lug nuts from the front wheel.

The wheel lug nuts should be torqued to 85 ft-lbs when the wheels are put back on the car.

Pull the front wheel off the wheel lugs and set it aside.

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Step 2

              Front Brake Pads

Lock springs (P/N 664822, shown in red) hold the caliper pad pins in place, which in turn hold the brake pads inside the caliper. The lock springs are inserted through a small hole in the head of the pin.
Insert the tip of a skinny screwdriver in the eyeholes of the clips and lift them off of the pins or pull with a pair of needle nose pliers.

Lock springs (P/N 664822, shown in red) hold the caliper pad pins in place, which in turn hold the brake pads inside the caliper. The lock springs are inserted through a small hole in the head of the pin.

Insert the tip of a skinny screwdriver in the eyeholes of the clips and lift them off of the pins or pull with a pair of needle nose pliers.

Step 3

Remove the two brake pad pins (P/N 1228810) by sliding them towards the car through their holes in the brake caliper. You may have to use a punch or screwdriver to get them moving and pliers to pull them through.
Be sure to collect the two damping springs (P/N 670567) on top of the pads when removing the pins, and note their orientation. These are under tension and can pop off, so be careful.

Remove the two brake pad pins (P/N 1228810) by sliding them towards the car through their holes in the brake caliper. You may have to use a punch or screwdriver to get them moving and pliers to pull them through.

Be sure to collect the two damping springs (P/N 670567) on top of the pads when removing the pins, and note their orientation. These are under tension and can pop off, so be careful.

Step 4

Using your hands or a screwdriver, lift the inner and outer brake pads out of the brake caliper.
If you’re prying the pads, be careful applying leverage to the disc or caliper as not to damage them. Make sure to remove any backing plates the pads may have.

Using your hands or a screwdriver, lift the inner and outer brake pads out of the brake caliper.

If you’re prying the pads, be careful applying leverage to the disc or caliper as not to damage them. Make sure to remove any backing plates the pads may have.

Step 5

Before installing new brake pads, you will need to compress the brake caliper pistons (shown in red) so that the pads fit inside the caliper.
Use a chisel, pry bar, or universal fence clamp to gently push the pistons away from the brake rotor and flush with the caliper.

Before installing new brake pads, you will need to compress the brake caliper pistons (shown in red) so that the pads fit inside the caliper.

Use a chisel, pry bar, or universal fence clamp to gently push the pistons away from the brake rotor and flush with the caliper.

Step 6

When installing the new brake pads, make sure that they are properly seated in the caliper. If they are not, then the dowels will not go back in correctly. You may need to give them a light tap with mallet to get them fully seated.
Apply brake part lubricant to the back of pads and around pins to prevent squeaking, keeping away from pad material and rotors.
After completing installation and vehicle is on the ground, pump brakes a few times to re-seat pistons and confirm braking pressure before moving.

When installing the new brake pads, make sure that they are properly seated in the caliper. If they are not, then the dowels will not go back in correctly. You may need to give them a light tap with mallet to get them fully seated.

Apply brake part lubricant to the back of pads and around pins to prevent squeaking, keeping away from pad material and rotors.

After completing installation and vehicle is on the ground, pump brakes a few times to re-seat pistons and confirm braking pressure before moving.

To reassemble your device, follow these instructions in reverse order, starting at step 4.

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                    David Hodson

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Introduction#

What you need#

Introduction

What you need