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SPA XC90 DIY Brake Pad Replacement with pics

128K views 161 replies 69 participants last post by  trizzuth  
#1 · (Edited)
Replaced front & back pads on our 2018 XC90. We're at 30k miles and had our last free service. Dealer indicated that 2-3mm remain and quoted $800 for the whole job.

Tools needed:
- 7mm allen key for back brakes
- 11mm allen key for front brakes (I used a Torx T55 driver, however)
- Medium C clamp
- Large C clamp
- Piece of aluminum bar (or other, to place against brake piston)
- Small flat head screw driver
- Breaker bar or large ratchet
- 19mm socket, small extension
- Torque wrench capable of 100 ft-lbs (lug nut spec is 103 ft-lbs)
- Needle nose pliers (or special brake piston tool)
- Jack
- Jack stand
- Wheel blocks
- 9v battery, a couple wires (more on this later)
- Brake caliper grease (optional)
- Shop towels, paper towels, gloves

References:
Front Brake Pad Video

Back Brake Video

Electric Parking Brake reset video

Jack points
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Preparation:
Remove cap from brake master cylinder in engine bay

Rear Brake Steps:
[1] Remove lug nut caps with the Volvo supplied tool (look in glove box)
[2] Loosen lug nuts with 19mm socket and breaker bar (use volvo supplied key for the lock nut, look in your trunk)
[3] Use jack to elevate vehicle
[4] Place jack stand under sturdy/strong element of suspension or body as backup
[5] Remove wheel
[6] Pop off dust covers from both caliper bolts
[7] Remove the retaining spring, use a flat screw driver if needed
[8] Remove caliper bolts with 7mm allen key & ratchet
[9] Pop off yellow cover and remove parking brake wire
[10] Remove old pads
[11] Push in brake piston with C clamp
[12] Screw in brake piston with hand tools, or use dedicated brake piston tool. Clockwise until the piston stops.
[13] Spin back parking brake with 9v battery and wires (positive to 'top' pin of parking brake inner plug, negative to bottom)
[14] Install new pads (optional: apply grease to the lugs on each end of the pad)
[15] Reinstall everything in reverse older. Torque lug nuts to 103 ft lbs.

Front Brake Steps:
[1] Wheel removal and use of jack as before
[2] Pop off dust covers from both caliper bolts
[3] Remove the retaining spring, use a C clamp to ease pressure on center portion of spring (squeeze toward outer edge of caliper)
[4] Remove caliper bolts with 11mm allen key & ratchet (or T55 Torx)
[5] Remove old pads
- Inner pad comes out easily (held by springs)
- Outer pad may appear to be stuck if it was installed with 3M VHB tape. Tap it loose with a hammer.
[6] Push in brake piston with C clamp (no need to screw it in)
[7] Install new pads (optional: apply grease to the lugs on each end of the pad)
- Inner pad has springs, it will require both hands to get this done. I used a 5gal bucket to support the caliper during this step
- The outer pad may come with 3M VHB tape applied. If so, clean the caliper first with brake parts cleaner.
[8] Reinstall everything in reverse older. Torque lug nuts to 103 ft lbs.

Don't forget to put the lid back on the master brake cylinder!

Notes:
- There is no place to hang the calipers as with some other vehicles. No holes, hooks, springs - can't use the coat-hanger trick! Be careful with that brake hose.
- The back caliper is quite light and easier to work with
- Front caliper is heavy, I used a 5gal bucket as my helping hand
- The front caliper spring is stiff. Getting it off required a C clamp to ease the tension in the middle. Getting it back on required very firm pressure to bend the arms back over the caliper.
- To wind back the parking brake I used a 9v battery. It is also possible to remove the parking brake assembly if you prefer, then wind it back manually. Leave the parking brake off!

Location of master brake cylinder under hood
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Cover popped off. Unscrew the lid.
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Back wheel jack point at the side of the car (see previous diagram)
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Removing lug nut covers with supplied tool
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Removing lug nuts with 19mm socket
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Jack stand in the back. I found a sturdy looking bar and rested the weight of the vehicle on both the jack and the stand.
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Removing parking brake wire lock (yellow)
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Parking brake wire open. If using 9v battery to rewind, connect positive to the upper inner post, negative to the lower post.
(NOT on the yellow plug, but on the plug that's part of the caliper)
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Pop off caliper bolt dust covers
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7mm allen key for rear brake caliper bolts
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Caliper bolts loose
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Rear brake caliper removed. Note piston and the little dimples that will be used to screw it in after pushing in with C clamp.
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Push in rear piston with C clamp. Likely you won't get it in all the way... I had a quarter inch remaining
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Caliper grease for good luck! I only applied to the little lugs at the end of each pad (ie. where they ride on the caliper)
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After pushing in the back piston you may need to screw it in. There are dedicated tools but something else may work.
I used the tool that came with my angle grinder, it fit perfectly. Needle nosed pliers is another option.
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Some grease on the ends of the pads, only the part that rides against the caliper
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Peel any plastic backing from the pads prior to installation
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Use of torque wrench. I set it to 100 ft-lbs, close enough IMO.
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Front Jack Point, the raised area with the two large holes
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Additional side lift point, toward the back. Don't know what it's for. Could use it for jack stand...
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Front caliper assembly. Note the position of the spring, you'll need to get it back. Very stiff!
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I used a torx T55, 11mm allen is supposed to be the proper tool
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Backing out the front caliper bolts. When installing them again, I just made them "good n tight", don't know torque.
(They are not particularly tight)
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Use of C clamp to remove the caliper spring makes removal easier. Otherwise it's stuck a little groove in the middle.
(Did not use during assembly)
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The new pads. Inner pad has the springs, outer pad has 3M VHB tape. Remove that paper prior to assembly.
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Front caliper supported by a 5gal bucket and a sand bag. I later use shop towels instead of the bag, worked better.
(You will need this unless you have a helper. Installing the inner pad requires pushing it in with both hands.)
(Ignore the screw driver, it's just to hold the caliper steady - not needed)
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Remove paper from 3M VHB adhesive. Clean the caliper prior to putting in this pad, it is the outer.
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Some grease on the ends of the pad plate
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Both pads in place, front caliper. They're not going to move!
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#146 ·
Yeah I'm not sure where I got the idea about ceramic being more prone to rotor deposits. I wanted the initial bite of the semi-metallics, but these Brembos were a bad choice. They're crazy squeaky in any cooler weather below ~45F.
The squeaking is from not putting that rubbery/gummy thing behind the pads touching the brake pistons. Also, you want to make sure the piston surface is completely clean and flat prior to spraying that rubbery/gummy anti-squeal thing.

My brembo ceramics lasted slightly longer than the OEM pads and rotors when it comes to pulsating. But man, when the pulsating did occur, the tires sounded like they were going to shred. The pulsating was much worse than the OEM set up. So if that’s not deposits, then it’s rotors warping. Unless I’m missing something.
Rotors rarely warp unless you've been racing at a track, heated them up, didn't do a proper cool down and then the pads are sitting on one spot on the rotor when you parked your hot car.

Any time I get brake pad deposits, I either let miles wear them out OR I go drive as safely fast as I can and STOMP on the brakes with ABS until completely stopped 5 times. If it's still there, then I do the same but "threshold" brake (almost at the point of engaging ABS) 5 times.

If you're still having issues despite above, then your issue is that your rotor and wheel is not sitting flush with each other since the bolts were improperly torqued (for ex, 2 bolts are tightened A LOT more than the other 3 or that each bolt was tightened completely vs sitting each of the 5 bolts a little at a time until torqued).

Ask me how I know the above... ;)
 
#147 ·
The squeaking is from not putting that rubbery/gummy thing behind the pads touching the brake pistons. Also, you want to make sure the piston surface is completely clean and flat prior to spraying that rubbery/gummy anti-squeal thing.



Rotors rarely warp unless you've been racing at a track, heated them up, didn't do a proper cool down and then the pads are sitting on one spot on the rotor when you parked your hot car.

Any time I get brake pad deposits, I either let miles wear them out OR I go drive as safely fast as I can and STOMP on the brakes with ABS until completely stopped 5 times. If it's still there, then I do the same but "threshold" brake (almost at the point of engaging ABS) 5 times.

If you're still having issues despite above, then your issue is that your rotor and wheel is not sitting flush with each other since the bolts were improperly torqued (for ex, 2 bolts are tightened A LOT more than the other 3 or that each bolt was tightened completely vs sitting each of the 5 bolts a little at a time until torqued).

Ask me how I know the above... ;)
In my defense, the dealer replaced the brakes each time. Getting the dealer’s techs to properly torque an oil filter housing is a stretch. So I’m sure the brakes were given the same half ass treatment 🙄.

I’m probably going to do the brakes myself the next time they’re needed though. Brakes don’t scare me. Volvo and Volvo’s bizarre way of making things difficult does.
 
#151 ·
Followed the write up and changed front and rear - pads and rotors on our 2020 XC90 a little while back. Used the manual wind back of the park brake after remove the electric motor. All worked well and straight forward.
The caliper bolts on the front require a bit of muscle. Turned the wheel out for more clearance. I found the Caliper bolts on the rear awkward and ended up using an impact wrench with an offset. Battery impact wrench turned something painful into a non-event.
Changed to ATE rotors and ATE ceramic pads all around. Performing well and not noticed any difference in feel to the original Volvo.
 
#152 ·
Also just completed the rear brake pad replacement (fronts done a few months ago) on a 2017 XC90. Most people seem to advocate one of three ways to retract the rear EPB:
  • put the car in service mode with software (VIDA/Orbit/VDASH etc.)
  • disconnect the motor and manually unwind
  • disconnect the EPB motor terminals and connect a battery of some sort to the motor in reverse polarity to retract

I haven't seen it mentioned here yet but there is a way to retract the EPB just from the cockpit which is IMO the simplest and what I eventually used. No wires, batteries, tools or software required :)

There are a few videos around showing this process, but it goes like this:
  1. Turn and hold (or push and hold) the start/stop for 5 seconds to put the car in Ignition position II
  2. Press brake pedal and release park brake. This step is critical and not mentioned in the videos that I found; I could not get this process to work unless I started the process with the park brake released.
  3. Press and hold the accelerator pedal (do not release until step 7)
  4. Press and hold the park brake release (do not release until step 7)
  5. Turn off ignition
  6. Turn ignition back on to position II (hold for 5 seconds)
  7. EPB should go into service mode with the park brake symbol flashing
return to normal mode is the same thing but pull the park brake control instead of push
 
#160 ·
Second time replacing front rotors and pads. 92K miles. First time was around 55K miles. 37K miles later, the inner pads are down to bare metal. Ordered blue box replacements again from FCP. Rotors are still made in Sweden and pads from Italy. New pads had spacer springs, which only the rears had before (IIRC). Paid the shop to do the job and got my store credit today. I was skeptical when I first started using FCP, but they have always come through with their lifetime warranty. A huge asset for folks who tend to keep their cars forever.
 
#162 ·
^^ that video was GOLDEN for me above, got to do the entire e-parking brake thing right from the driver's seat, worked like a charm! tested it all out before doing the job and it worked perfectly, saved me a bunch of time. Also had to go out and buy an 11mm allen socket before doing the job as I did not have anything above 10 in stock nor a 7/16 one which would have been close enough. Fronts calipers were a bear to remove since there was basically no pad left and the pistons had compressed all the way, even had to remove some brake fluid from the reservoir once I got to the fronts after compressing one side the reservoir was just about at the top... Re-used the rotors since they were still good, next time she gets new rotors and pads, which are now LIFETIME since FCP.

When have you ever seen brake pads worn down this much, with this tiny of a sliver of pad left, yet not all the way through to the backing plate? MIRACULOUS I caught this and changed them yesterday when I did, this car has no brake pad wear squealer, no brake pad electrical circuit for a warning light, it just starts making a grinding noise and by that time, you have what you see here!!!

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