Replacing front brake discs and pads on a Volvo XC90 is a rewarding DIY job that saves significantly over a main dealer. The XC90 uses a conventional sliding pin caliper with 7mm Allen key slider pins.
The process is very similar to most European vehicles. The key things to note are the short bottom slider pin versus the longer top pin — these must not be swapped — and the importance of pushing the caliper piston fully back before removal.
When You Need This Job
- Squealing or grinding noise when braking
- Vibration through the brake pedal under braking
- Brake pad wear warning light on dashboard
- Visible lip or groove on the disc edge
- Pad thickness below 3mm on inspection
- Pulling to one side under braking
Tools You'll Need
Step-by-Step Guide
Remove the wheel
Raise the vehicle, support on axle stands and remove the front wheel to expose the disc and caliper assembly.
Remove the slider pin dust caps
At the rear of the caliper are two rubber dust grommets covering the slider pin heads. Pull these out to expose the Allen key sockets.
Undo both slider pins with a 7mm Allen key
Insert a 7mm Allen key and unscrew both pins. Note that the bottom pin is shorter than the top — keep them separate. If stiff, wiggle while unscrewing.
Push the piston back
Remove the brake fluid reservoir cap. Use a flat screwdriver against the old pad face to slowly push the piston all the way back into the caliper body.
Remove the spring clip at the front
There is a spring clip at the front of the caliper with a centre clip and two end clips. Pop all three out and set aside.
Remove the caliper and hang it up
Wiggle the caliper off the disc. Hook it up with a bungee cord to a suspension component to take the weight off the brake hose.
Tap out the old pads
The pads can be tapped out of the carrier. Inspect — inner pad gone to metal is a common finding on these.
Remove the disc retaining bolt and disc
One 10mm bolt holds the disc. Remove it and tap the disc off with a rubber mallet if stuck.
Clean all mating surfaces
Wire brush the hub face, caliper carrier and pad sliding surfaces. Use a Dremel or file on any raised rust so new pads have a clean flat surface. Use brake cleaner.
Fit the new disc
Slide the new disc on and refit the 10mm retaining bolt.
Fit pads with brake grease
Apply a small amount of brake grease to the pad backing plate ends only. Clip the pads into the carrier spring clips.
Refit caliper and slider pins
Slide the caliper over the disc, ensuring pads locate correctly. Clean and lightly grease the slider pins. Fit short pin in the bottom, long pin in the top. Torque down. Refit dust caps and spring clip.
Refit wheel and bed in brakes
Torque the wheel nuts. Pump the brake pedal several times until firm before moving. Carry out gentle stops from 30mph to bed in the new components.
Torque Specifications
Corroded or pitted slider pins cause uneven pad wear and brake pulling. If the pins are rough or pitted replace them — they are inexpensive.
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