Recommended replacement interval for the part category Brake disc : 50000 km

Important!

This replacement procedure can be used for:
VOLVO V40 Box Body / Hatchback (525, 526) 2.0 D3, VOLVO V40 Box Body / Hatchback (525, 526) 2.0 D4, VOLVO V40 Box Body / Hatchback (525, 526) 1.6 D2/ DRIVe … 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 V40 Box Body / Hatchback (525, 526) and other VOLVO models

Brake disc

        Brake disc for VOLVO V40 Box Body / Hatchback (525, 526) 2.0 D3 Diesel (150 hp)
      
        Brake disc for VOLVO V40 Box Body / Hatchback (525, 526) 2.0 D4 Diesel (177 hp)
      
        Brake disc for VOLVO V40 Box Body / Hatchback (525, 526) 1.6 D2/ DRIVe Diesel (114 hp)

Replacement: brake discs – VOLVO V40 Kasten / Schrägheck (525, 526). List of the tools you'll need:

                        Wire brush
                      
                        WD-40 spray
                      
                        Brake cleaner 
                      
                        Anti-squeal paste
                      
                        Copper grease 
                      
                        Drive socket # 13 
                      
                        HEX bit no.H7.
                      
                        Wheel impact socket #19
                      
                        Brake caliper wind back tool
                      
                        Ratchet wrench
                      
                        Torque wrench
                      
                        Tap wrench
                      
                        Rubber mallet
                      
                        Crow bar
                      
                        Wheel chock

Buy tools

Replacement: brake discs – VOLVO V40 Kasten / Schrägheck (525, 526). AUTODOC recommends:

Replace the brake disks on the car VOLVO V40 Kasten / Schrägheck (525, 526) 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.
Warning! Shut down the engine before starting any work – VOLVO V40 Kasten / Schrägheck (525, 526).

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.

Replacement: brake discs – VOLVO V40 Kasten / Schrägheck (525, 526). Tip:
To avoid injury, hold up the wheel when unscrewing the bolts.
Step 6

Remove the wheel.
Step 7

Remove the dust boot caps of the brake caliper guide pins. Use a crowbar.
Step 8

Unscrew the brake caliper fastening. Use HEX No.H7. Use a ratchet wrench.
Step 9

Detach the brake caliper retaining spring. Use a crowbar.
Step 10

Remove the brake caliper. Use a crowbar.

Replacement: brake discs – VOLVO V40 Kasten / Schrägheck (525, 526). 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.
Step 11

Remove the brake pads. Use a crowbar.
Step 12

Clean the brake caliper bracket fasteners. Use a wire brush. Use WD-40 spray.
Step 13

Unscrew the caliper bracket fastening. Use a drive socket #13. Use a ratchet wrench. Use a tap wrench.
Step 14

Remove the caliper bracket.
Step 15

Remove the brake disc. Use a rubber mallet.
Step 16

Clean the brake caliper bracket from dirt and dust. Use a wire brush. Use a brake cleaner.

Replacement: brake discs – VOLVO V40 Kasten / Schrägheck (525, 526). Tip from AUTODOC:
After applying the spray, wait a few minutes.
Step 17

Clean the hub. Use a wire brush. Treat the contacting surface. Use copper grease.
Step 18

Install the brake disc.
Step 19

Install the brake caliper bracket.
Step 20

Tighten the brake caliper bracket. Use a drive socket #13. Use a torque wrench. Tighten it to 70 Nm torque.
Step 21

Treat the brake caliper piston. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake discs – VOLVO V40 Kasten / Schrägheck (525, 526). After applying the spray, wait a few minutes.
Step 22

Press in the brake caliper piston. Use brake caliper wind back tool.
Step 23

Treat the brake pads in the area where their surface comes into contact with the brake caliper bracket. Use anti-squeal paste.

Step 24

Install the brake pads.
Step 25

Install the brake caliper and fix it. Use HEX No.H7. Use a torque wrench. Tighten it to 35 Nm torque.
Step 26

Install the dust boot caps of the brake caliper guide pins.
Step 27

Install the brake caliper retaining spring. Use a rubber mallet.
Step 28

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 29

Clean the brake disk surface. Use a brake cleaner.

Replacement: brake discs – VOLVO V40 Kasten / Schrägheck (525, 526). Professionals recommend:
After applying the spray, wait a few minutes.
Step 30

Install the wheel.

AUTODOC recommends:
Important! Hold the wheel while screwing in the fastening bolts. VOLVO V40 Kasten / Schrägheck (525, 526)
Step 31

Screw in the wheel bolts. Use wheel impact socket #19.
Step 32

Lower the car and working in a cross order, tighten the wheel bolts. Use a torque wrench. Tighten it to 110 Nm torque.
Step 33

Remove the jacks and chocks.

Replacement: brake discs – VOLVO V40 Kasten / Schrägheck (525, 526). AUTODOC recommends:
Check the brake fluid level in the expansion tank and refill if necessary.
Step 34

Tighten the brake fluid reservoir cap.

AUTODOC recommends:
VOLVO V40 Kasten / Schrägheck (525, 526) – Without starting the engine, press the brake pedal several times until it feels firm.
Step 35

Close the hood.

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