2001 Volvo S40 rear brake rotors, pads

REAR BRAKE DISC
CAUTION:On front and rear, manufacturer recommends replacing caliper mounting bracket (holder) bolts, if loosened or removed.

Removal
Remove hub cap and wheel.
Remove brake pads.
Remove caliper holder assembly and caliper. Suspend it with a piece of wire so that brake hose will not be damaged.
NOTE:Do not depress brake pedal when brake pads have been removed.
Remove retaining bolt and brake disc.

Inspection
Check that hub flange is clean.
Remove rust with steel wool or a wire brush.
Inspect hub. If hub is damaged, measure its lateral runout. See MEASURING LATERAL RUNOUT IN HUB under SERVICING.
Installation
Fit new brake disc on hub and tighten retaining bolt to specification. See TORQUE SPECIFICATIONS .
Install caliper holder assembly and caliper. Use NEW bolts and tighten to specification. See TORQUE SPECIFICATIONS .
Install brake pads. See REAR DISC BRAKE PADS . Check parking brake as necessary.
Install wheel.

REAR DISC BRAKE PADS
Removal
Remove hub cap and wheel.
Remove retaining clip and brake hose from support.
Remove upper bolt from locating pin for brake caliper.
Twist brake caliper backwards. Remove brake pads. Inspection
Clean brake pad contact surfaces in brake caliper and on caliper mounting.
Check piston dirt guard.
Replace dirt guard if it is worn. Recondition brake caliper if dirt guard is defective. If dirt guard is defective, dirt may have penetrated cylinder. Therefore brake caliper must be reconditioned. See REAR BRAKE CALIPER under OVERHAUL.
NOTE:If installing new brake pads, ensure minimum disc thickness meets specification. See DISC BRAKE SPECIFICATIONS .

Check brake disc surface. Check lateral runout of brake disc. If disc is uneven. Replace brake disc if it is worn or grooved.
Check rubber sleeves on locating pins. Replace if necessary. If necessary, lubricate locating pins using silicon grease. Insert locating pins in rubber sleeves. Locating pins must slide into sleeves easily.
Rotating Brake Piston Into Caliper
Block brake caliper against brake disc.
Turn plate (A) forward over shaft and insert tool.
Install lugs (B) in cut-out in brake piston. See Fig. 32 .
Turn shaft (C) so that plate (A) pressed against brake caliper.
Turn axle (D) to right and press he piston back while turning shaft (C) to right so that plate (A) is in contact with brake caliper.
Turn brake piston back fully and remove tool.
Fig. 32: Rotating Brake Piston Into Caliper
Courtesy of VOLVO CARS OF NORTH AMERICA.

Installation
Install wear indicator (A) on under side of inner installed brake pads. Install brake pads.
Position brake caliper. Install new locking bolt and tighten to specification. See TORQUE SPECIFICATIONS .
Install brake hose in support. Install retaining clip.
Install wheels.