How to change rear brake discs on VOLVO S60 I (384) – replacement guide
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Recommended replacement interval for the part category Brake disc : 50000km
Important!
This replacement procedure can be used for:
VOLVO S60 I (384) 2.4,
VOLVO S60 I (384) 2.4,
VOLVO S60 I (384) 2.4 T,
VOLVO S60 I (384) T5,
VOLVO S60 I (384) D5,
VOLVO S60 I (384) 2.4 T AWD,
VOLVO S60 I (384) 2.0 T,
VOLVO S60 I (384) 2.4 Bifuel (CNG),
VOLVO S60 I (384) 2.4 D,
VOLVO S60 I (384) 2.5 T,
VOLVO S60 I (384) 2.5 T AWD,
VOLVO S60 I (384) T5,
VOLVO S60 I (384) D5,
VOLVO S60 I (384) 2.4 D,
VOLVO S60 I (384) T5,
VOLVO S60 I (384) 2.4,
VOLVO S60 I (384) 2.4 D,
VOLVO S60 I (384) 2.4 Bifuel (LPG),
VOLVO S60 I (384) 2.4 CDI
…
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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 S60 I (384) and other VOLVO models
Replacement: brake discs – VOLVO S60 I. Tip from AUTODOC experts:
Replace the brake disks on the car VOLVO S60 I 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.
Please note: all work on the car – VOLVO S60 I – should be done with the engine switched off.
Carry out replacement in the following order:
Step 1
Open the bonnet. Unscrew the brake fluid reservoir cap.
Step 2
Secure the wheels with chocks.
Step 3
Loosen the wheel mounting bolts. Use wheel impact socket #19.
Step 4
Raise the rear of the car and secure on supports.
Step 5
Unscrew the wheel bolts.
AUTODOC recommends:
Warning! To avoid injury, hold the wheel while unscrewing the fastening bolts. VOLVO S60 I
Step 6
Remove the wheel.
Step 7
Spread the brake pads. Use a crowbar.
Step 8
Remove the dust boot caps of the brake caliper guide pins. Use a crowbar.
Step 9
Unscrew the brake caliper fastening. Use HEX No.H7. Use a ratchet wrench.
Step 10
Detach the brake caliper retaining spring. Use a crowbar.
Step 11
Remove the brake caliper.
Replacement: brake discs – VOLVO S60 I. Tip from AUTODOC experts:
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.
Step 12
Remove the brake pads. Use a crowbar.
Step 13
Clean the brake caliper bracket fasteners. Use a wire brush. Use WD-40 spray.
Step 14
Unscrew the caliper bracket fastening. Use a drive socket #13. Use a tap wrench. Use a ratchet wrench.
Step 15
Remove the caliper bracket.
Step 16
Clean the brake disk surface. Use a wire brush. Use WD-40 spray.
Step 17
Unscrew the brake disc fastening. Use a drive socket #10. Use a ratchet wrench.
Step 18
Remove the brake disc.
Step 19
Clean the hub. Use a wire brush. Treat the contacting surface. Use copper grease.
Step 20
Install the brake disc.
Step 21
Tighten the brake disc fastening. Use a drive socket #10. Use a torque wrench. Tighten it to 9 Nm torque.
Step 22
Clean the brake caliper bracket from dirt and dust. Use a wire brush. Use a brake cleaner.
AUTODOC recommends:
Replacement: brake discs – VOLVO S60 I. After applying the spray, wait a few minutes.
Step 23
Install the brake caliper bracket.
Step 24
Tighten the brake caliper bracket. Use a drive socket #13. Use a torque wrench. Tighten it to 60 Nm torque.
Step 25
Treat the brake caliper piston. Use a brake cleaner.
Replacement: brake discs – VOLVO S60 I. Tip from AUTODOC:
After applying the spray, wait a few minutes.
Step 26
Press in the brake caliper piston. Use brake caliper wind back tool.
Step 27
Install the brake pads.
Step 28
Install the brake caliper and fix it. Use HEX No.H7. Use a torque wrench. Tighten it to 30 Nm torque.
Step 29
Install the dust boot caps of the brake caliper guide pins.
Step 30
Install the brake caliper retaining spring. Use a rubber mallet. Use a crowbar.
Step 31
Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 32
Clean the brake disk surface. Use a brake cleaner.
AUTODOC recommends:
Replacement: brake discs – VOLVO S60 I. After applying the spray, wait a few minutes.
Step 33
Install the wheel.
AUTODOC recommends:
Warning! To avoid injury, hold the wheel while screwing in the fastening bolts on the car. VOLVO S60 I
Step 34
Screw in the wheel bolts. Use wheel impact socket #19.
Step 35
Lower the car and working in a cross order, tighten the wheel bolts. Use a torque wrench. Tighten it to 140 Nm torque.
Step 36
Remove the jacks and chocks.
Replacement: brake discs – VOLVO S60 I. Tip from AUTODOC experts:
Without starting the engine, press the brake pedal several times until you feel significant resistance.Check the brake fluid level in the expansion tank and refill if necessary.
Step 37
Tighten the brake fluid reservoir cap. Close the hood.
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