When to replace the Brake Discs on your VOLVO S40
Recommended replacement interval for the part category Brake disc : 50000 km
Important!
This replacement procedure can be used for:
VOLVO S40 II (544) D3, VOLVO S40 II (544) D4, VOLVO S40 II (544) D2, VOLVO S40 II (544) 2.0 F, VOLVO S40 II (544) 2.4, VOLVO S40 II (544) 2.4, VOLVO S40 II (544) T5, VOLVO S40 II (544) 2.0 D, VOLVO S40 II (544) T5 AWD, VOLVO S40 II (544) 1.8, VOLVO S40 II (544) 1.6, VOLVO S40 II (544) 1.6 D, VOLVO S40 II (544) 2.0, VOLVO S40 II (544) D5, VOLVO S40 II (544) T5, VOLVO S40 II (544) T5 AWD, VOLVO S40 II (544) 1.8 FlexFuel, VOLVO S40 II (544) D4, VOLVO S40 II (544) 2.0 CDI, VOLVO S40 II (544) 2.4 CDI, VOLVO S40 II (544) 1.9 View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

All the parts you need to replace – Brake Discs for S40 II (544) and other VOLVO models
Tools
Replacement: brake discs – VOLVO S40 II (MS). Tools you need:
Wire brush
WD-40 spray
Brake cleaner
Copper grease
HEX bit no.H7.
Drive socket # 15
Wheel impact socket #19
Brake caliper wind back tool
Ratchet wrench
Torque wrench
Tap wrench
Crow bar
Wheel chock
Replacement: brake discs – VOLVO S40 II (MS). Tip from AUTODOC experts:
  • Replace the brake disks on the car VOLVO S40 II (MS) in complete set for each axis. Regardless of the state of components. This will ensure even braking.
  • The replacement procedure is identical for both brake disks on the same axle.
  • When changing the brake discs, always replace the brake pads.
  • All work should be done with the engine stopped.
Replacement: brake discs – VOLVO S40 II (MS). Take the following steps:
  1. Step 1
    How to change Brake Discs on Volvo S40 Mk2 2004 - free PDF and video manuals
    Open the bonnet. Unscrew the brake fluid reservoir cap.
  2. Step 2
    How to replace VOLVO S40 II (544) 2.0 D 2005 Brake Discs - step-by-step manuals and video guides
    Secure the wheels with chocks.
  3. Step 3
    Volvo S40 Mk2 1.6 D 2006 Brake Discs replacement: free workshop manuals
    Loosen the wheel mounting bolts. Use wheel impact socket #19.
  4. Step 4
    Raise the front of the car and secure on supports.
    Step 5
    Changing Brake Discs on VOLVO S40 II (544) 1.8 2007 by yourself
    Unscrew the wheel bolts.
    Replacement: brake discs – VOLVO S40 II (MS). Tip:
    To avoid injury, hold up the wheel when unscrewing the bolts.
  5. Step 6
    How to remove VOLVO S40 1.8 FlexFuel 2008 Brake Discs - online easy-to-follow instructions
    Remove the wheel.
  6. Step 7
    How to replace Brake Discs on VOLVO S40 II (544) 2009: download PDF manuals and video instructions
    Remove the dust boot caps of the brake caliper guide pins. Use a crowbar.
  7. Step 8
    How hard is it to do yourself: Brake Discs replacement on Volvo S40 Mk2 1.6 2010 - download illustrated guide
    Unscrew the brake caliper fastening. Use HEX No.H7. Use a ratchet wrench.
  8. Step 9
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    Detach the brake caliper retaining spring. Use a crowbar.
  9. Step 10
    Changing of Brake Discs on Volvo S40 Mk2 2012 won't be an issue if you follow this illustrated step-by-step guide
    Spread the brake pads. Use a crowbar.
  10. Step 11
    VOLVO S40 D5 Brake Discs replacement: online guides and video tutorials
    Remove the brake caliper.
    Replacement: brake discs – VOLVO S40 II (MS). AUTODOC experts recommend:
    Tie the caliper to the suspension or to the body with a wire without disconnecting from the brake hose to prevent depressurization of the brake system.Make sure that the brake caliper is not hanging on the brake hose.Don't press the brake pedal after the brake caliper has been removed. As a result, the piston can fall out from the brake cylinder, and brake fluid leakage and depressurization of the system may occur. Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary.
  11. Step 12
    Replacing Brake Discs on Volvo S40 Mk2 2005 2.0 D by yourself
    Remove the brake pads. Use a crowbar.
  12. Step 13
    S40 II (544) 1.8 FlexFuel 2006 Brake Discs DIY replacement workshop manual
    Clean the brake caliper bracket fasteners. Use a wire brush. Use WD-40 spray.
  13. Step 14
    How to change Brake Discs on VOLVO S40 II (544) 2007 - tips and tricks
    Unscrew the caliper bracket fastening. Use a drive socket #15. Use a ratchet wrench. Use a tap wrench.
  14. Step 15
    Step-by-step recommendations for DIY replacement Volvo S40 Mk2 2008 1.8 FlexFuel Brake Discs
    Remove the caliper bracket.
  15. Step 16
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    Remove the brake disc.
  16. Step 17
    How to change Brake Discs on Volvo S40 Mk2 2004 - free PDF and video manuals
    Clean the hub. Use a wire brush. Treat the contacting surface. Use copper grease.
  17. Step 18
    How to replace VOLVO S40 II (544) 2.0 D 2005 Brake Discs - step-by-step manuals and video guides
    Install the brake disc.
  18. Step 19
    Volvo S40 Mk2 1.6 D 2006 Brake Discs replacement: free workshop manuals
    Clean the brake caliper bracket from dirt and dust. Use a wire brush. Use a brake cleaner.
    AUTODOC recommends:
    Replacement: brake discs – VOLVO S40 II (MS). After applying the spray, wait a few minutes.
  19. Step 20
    Changing Brake Discs on VOLVO S40 II (544) 1.8 2007 by yourself
    Install the brake caliper bracket.
  20. Step 21
    How to remove VOLVO S40 1.8 FlexFuel 2008 Brake Discs - online easy-to-follow instructions
    Tighten the brake caliper bracket. Use a drive socket #15. Use a torque wrench. Tighten it to 120 Nm torque.
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