I'm planning on replacing the pads (and probably the rotors)

Hi,

Replacing front brake pads and rotors isn't too hard of a job. In general, you can expect the brakes to last about 25000 miles. It has become common to replace brake rotors every time pads are replaced. However, if you have no brake pulsation or shaking in the steering and the rotors are in good shape, they will likely last for another set of brake pads.

First, here is a link that shows in general how pads and rotors are replaced. You can use this as a guide.

https://www.2carpros.com/articles/how-to-replace-front-brake-pads-and-rotors-fwd

Here are the directions specific to your vehicle. The attached pics correlate with the directions.

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2007 Volvo S60 2.5T L5-2.5L Turbo VIN 59 B5254T2
Brake Pads Front, Replacing
Vehicle Brakes and Traction Control Disc Brake System Brake Pad Service and Repair Removal and Replacement Brake Pads Front, Replacing
BRAKE PADS FRONT, REPLACING
Brake pads front, replacing

Removal

Note! Minimum thickness for replacing the brake pads = 2 mm.

Remove the retaining spring and locating pins

pic 1

Remove:
- the retaining spring (3) carefully so that it does not deform
- the protective caps (1) from the two locating pins (2)
- the locating pins, use hex socket 7 mm.

Remove the brake caliper and brake pads

pic 2

Remove:
- the brake caliper from the holder
- the brake pads.
Hang the brake caliper by a steel wire from the front spring so as not to damage the brake hose.

Note! Do not depress the brake pedal while the brake pads are removed.

Clean and check the brake caliper and dust cover

pic 3

Clean and check the brake pad mating surfaces in the brake caliper and caliper holder.
Clean the sliding pins using a steel brush.
Check the piston dust boot. Replace the dust boot if it is damaged.

Note! If the dust boot is damaged dirt may have penetrated the cylinder. The brake caliper must be reconditioned. See Reconditioning front brake calipers See: Brake Caliper > Overhaul > Reconditioning Front Brake Calipers.

Check the brake disc

pic 4

Check brake disc friction surfaces.
If the brake disc displays signs of out-of-true, check its lateral run out. See Brake disc front, calibrating See: Brake Rotor/Disc > Component Tests and General Diagnostics > Brake Disc Front, Calibrating.
Replace the brake disc if it displays signs of heavy wear, variable thickness or similar. To replace, see Replacing front brake discs, B5244T5, B5254T2 See: Brake Rotor/Disc > Removal and Replacement > Replacing Front Brake Discs.

Note! Minimum recommended disc thickness / replacement limit = 23.0mm. Minimum recommended disc thickness when installing new brake pads = 23.8mm.For 16" brake discs the minimum thickness / replacement limit = 25mm. Minimum recommended disc thickness when installing new brake pads = 25.8mm.

Installation

Lubricating the sliding surfaces

pic 5

Lubricate the contact surfaces of the brake pads using silicone grease, part no. 1161687 (12 ml) or part no. 1161688 (50 ml)
(Do not lubricate the sliding pins)

Refit the brake lining and brake caliper

pic 6

Press piston back into cylinder on brake caliper.
Check that the dust cover is correctly positioned.

Install:
- new brake pads
- the brake caliper.

Install the locating pins in the brake caliper

pic 7

Check the rubber sleeves of the locating pins. Replace if necessary.
Insert the locating pins in the rubber sleeves.
Tighten the locating pins. Tighten to 30 Nm. Install the protective caps (1).
Install the retaining spring (3).

Check the brake fluid level in the reservoir

pic 8

Depress the brake pedal a few times. Check the level of the brake fluid reservoir.
Top up if necessary.

Mount the wheels.
Installing wheels See: Wheels > Removal and Replacement.

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Here are the directions for rotor replacement.

2007 Volvo S60 2.5T L5-2.5L Turbo VIN 59 B5254T2
Replacing Front Brake Discs
Vehicle Brakes and Traction Control Disc Brake System Brake Rotor/Disc Service and Repair Removal and Replacement Replacing Front Brake Discs
REPLACING FRONT BRAKE DISCS
Replacing front brake discs

Removal

Remove the securing spring and locating pins
See Brake pads front, replacing, B5244T5, B5254T2 See: Brake Pad > Removal and Replacement > Brake Pads Front, Replacing.

Remove the brake caliper and brake pads
See Brake pads front, replacing, B5244T5, B5254T2 See: Brake Pad > Removal and Replacement > Brake Pads Front, Replacing.

Remove the caliper holder and the brake disc

pic 9

Remove:
- both the mounting screws (4) for the caliper holder. Remove the holder
- the locating pin (5) and the brake disc.

Cleaning and inspection

pic 10

Note! Cleaning is important to prevent lateral runout at the brake disc.

Clean the hub flange before installing the new brake disc.
Check the hub. If it is damaged, measure the lateral runout. See Front wheel hub, measuring lateral runout See: Wheel Hub > Component Tests and General Diagnostics > Front Wheel Hub, Measuring Lateral Runout.

Installation

Install the brake disc

pic 11

Note! Be careful when handling the new brake disc. Careless handling can cause damage to the brake disc (out-of-true).

Install:
- the new brake disc. Tighten the locating pin (5). Tighten to 8 Nm
- the caliper holder. Use new mounting screws (4). Tighten to 100 Nm.

Install the brake pads and brake caliper
See Brake pads front, replacing, B5244T5, B5254T2 See: Brake Pad > Removal and Replacement > Brake Pads Front, Replacing.

Install the locating pins in the brake caliper
See Brake pads front, replacing, B5244T5, B5254T2 See: Brake Pad > Removal and Replacement > Brake Pads Front, Replacing.

Install the wheel
Installing wheels See: Wheels > Removal and Replacement

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I hope this helps. Let me know if you have other questions.

Take care and God Bless,

Joe