Swapping XC brakes for R Brembos

[Ocean Racer]

I started this job this afternoon.

I will make a few posts as a build thread :)

*Please note.
Images show the use of a small scissor jack for photo purposes.
Ensure you use a professional jack (I use a ProLift 2tonne trolley jack) and jack stands.
Do not rely on your spare scissor lift for this job.

Start.
Jacking the car up.
http://www.atpimage.com/cars/volvo/IMG_0044.jpg

Front
http://www.atpimage.com/cars/volvo/IMG_0045.jpg

Rear
http://www.atpimage.com/cars/volvo/IMG_0043.jpg

Wheel off
http://www.atpimage.com/cars/volvo/IMG_0046.jpg

Caliper & disc off and purging the brake fluid
http://www.atpimage.com/cars/volvo/IMG_0047.jpg

Fitting the Brembo R caliper
http://www.atpimage.com/cars/volvo/IMG_0048.jpg

More info coming.

[Ocean Racer]

Having learn't the hard way during the front left wheel job, I found the other side a complete breeze and I managed a full exchange within 1 hour.

The steps include:

1. Jack car up

2. Remove wheel (with 19mm socket for lug nuts)

3. Grab a bucket and place it under the brake hose line.

4. Using a 13mm spanner, loosen the clip side brake line anticlockwise. You will see this is the side closest to the pump on the other side of the bracket. This will leak brake fluid immediately once the hose is loose so make sure the bucket catches it. Pull the line out from the hose and keep vertical if possible. Brake fluid is lethal to paint and try to contain the drips.
http://www.atpimage.com/cars/volvo/IMG_0065.jpg

5. Remove the 2 bolts holding the caliper on.
http://www.atpimage.com/cars/volvo/IMG_0067.jpg

6. Tap off the caliper from the disk. Use force if needed

7. Remove the little caliper alignment nut ( located amongst the ring of lug nut holes)

8. Remove the disk with a little wiggle. Without singing 'Hot potato' or 'Big red car'

9. get some WD40 or degreaser and clean the hub.


INSTALLATION

You're now ready for the new parts.

Start with the reverse order to install the new Brembo stuff.
Only exception is at step 5. You will need to install alloy mount bracket first.
http://www.v70r.com/forums/uploads/1267793615/gallery_1685_289_222125.jpg

Look at the alloy bracket location:
http://www.atpimage.com/cars/volvo/IMG_0049.jpg

Remember, if you are doing this, you WILL need a little plastic spigot ring on the hub for the 18" Pegasus rims.
ALSO NOTE: XC RIMS DO NOT FIT WITH R BREMBOS

Left side R Brembo, stainless steel braided brake line, bolts, alloy Brembo bracket, Caliper, Power slot rotor.
http://www.atpimage.com/cars/volvo/IMG_0057.jpg

[Ocean Racer]

OK so now the new lines, R Brembo caliper and 330mm disc are installed.
http://www.atpimage.com/cars/volvo/IMG_0050.jpg

Make sure the little spigot ring is on the hub before installing the Pegasus wheels.

Here is a little comparison of the stock XC brakes and the new Brembos:
Stock is 286mm
R Brembo 330mm
(pic is deceiving!)
http://www.atpimage.com/cars/volvo/IMG_0053.jpg

Wheel on and time to do the other side:
http://www.atpimage.com/cars/volvo/IMG_0060.jpg

[Ocean Racer]

OK, now for the rears:

Standard XC rears with 18" Pegs.

http://www.atpimage.com/cars/volvo/IMG_0080.jpg


1. Start by making sure the car is in gear and the hand brake / E brake is OFF.
2. Start by removing the wheel.
http://www.atpimage.com/cars/volvo/IMG_0081.jpg

3. With the 13mm spanner, disconnect the brake line. Remember to loosen the brass side with spring clip. This is found on the pump side of the pictured bracket.
http://www.atpimage.com/cars/volvo/IMG_0082.jpg

4. With a 14mm socket, remove the 2 bolts holding the calipers. Once the calipers are loose, you will need to wriggle the calipers away from the disc. Make sure you dont splash brake fluid everywhere.
http://www.atpimage.com/cars/volvo/IMG_0085.jpg

5. The rear dust shields.
This is the only incompatible part when fitting R brakes to non R cars.
The dust shields wrap perfectly around the XC 286mm discs but are in the way when using R discs. The lip that protrudes outwards will rub against the disc and so it must be shaved off, swapped with an R shield or the "Adam" method, cut and bend with clippers. This is the easiest and real backyard method.
http://www.atpimage.com/cars/volvo/IMG_0088.jpg

6. Now that I have bent the outer edge back with pliers, make sure you cut and remove the front part of the shield with the trimmers to ensure the Brembo caliper will fit.
http://www.atpimage.com/cars/volvo/IMG_0089.jpg

7. Comparison between the 286mm XC caliper and the R Brembo 330mm disc underneath.
http://www.atpimage.com/cars/volvo/IMG_0090.jpg

8. Rear dust shield now finished and time for the 330mm disc to go on.
http://www.atpimage.com/cars/volvo/IMG_0091.jpg

9. Note the clearance of the dust shield. If you feel too intimidated by the appearance of this, then get a pair of R shields. I have a feeling a pair of XC90 V8 shields 'may' also do the trick. (yet to verify)
http://www.atpimage.com/cars/volvo/IMG_0092.jpg

10. Connect the new SS brake line to the R caliper first.
Install the new 330mm discs and make sure the little alignment bolt is firmly in place.
Now it is time to reconnect the SS brake line to the brass connector. This is the hardest part. Some remove the bracket but I like doing things the difficult way. :)
http://www.atpimage.com/cars/volvo/IMG_0093.jpg

[Ocean Racer]

And finally finished :)

I had to bed in the rear park brakes and what fun they were. I had them smoking hot and smelling the cabin during the process. [cool2]

http://www.atpimage.com/cars/volvo/IMG_0113.jpg

http://www.atpimage.com/cars/volvo/IMG_0106.jpg

[Ocean Racer]

Reserved 5

[ifnt420]

Did you put on the R steering stop bracket with the calipers?

http://www.v70r.com/forums/uploads/1267793615/gallery_1685_289_222125.jpg

[Ocean Racer]

Did you put on the R steering stop bracket with the calipers?

http://www.v70r.com/forums/uploads/1267793615/gallery_1685_289_222125.jpg

Yes mate, its on there.
I will post more pics and details tomorrow. [thumbup]

[ifnt420]

Make sure you cut off the bottom 3" of the bracket, otherwise its gonna hit and eat into the control arm.
Or you could install the steering stop limiter from the R, but your turning radius will suck... :o

Also did you get the vibration damper for the R caliper?

http://img100.exs.cx/img100/1431/1000909medium1pi.jpg

[Ocean Racer]

Make sure you cut off the bottom 3" of the bracket, otherwise its gonna hit and eat into the control arm.


So far no damage but I am keeping an eye on it. [thumbup]

[Chilled Man]

You dont needt that bracket at all if you reuse your bolts to mount the calipers ;)

[8pack]

Not to be too much of a school marm, but you really shouldn't be using that scissor jack to work on your car. Terribly dangerous especially if you need to apply any serious force to any of the bolts.........get some jack stands! I got the willys just looking at the pics and thinking of you working on the car relying on that scissor jack.....smooshed fingers, arms, ankles, legs all sorts of grisly possibilities....

Please be careful!

[BillAileo]

I've got to join in 8pack's expression of concern. In my youth I was under an XKE supported by such a jack that failed. I was extremely lucky, my toolbox was underneath with me and held the car up while I managed to get out without serious injury. Be safe....

[Ars Gladius]

Not that they are a sane substitution for proper jack stands, but there are additional supports made from 4x4s in addition to the screw-jack in the posted pics...

[8pack]

I saw the 4x4 in the rear brake pics and those are even scarier. Wood crushes and they weight of the car is on a 4x4 pad. not that the whole 4x4 would crush, but if the car rocked at all the edges top or bottom could crush and the whole thing teeter over....i didn't bring it up because I was already being a nervous nellie....but since you did!!:eek:

[Ocean Racer]

Not to be too much of a school marm, but you really shouldn't be using that scissor jack to work on your car. Terribly dangerous especially if you need to apply any serious force to any of the bolts.........get some jack stands! I got the willys just looking at the pics and thinking of you working on the car relying on that scissor jack.....smooshed fingers, arms, ankles, legs all sorts of grisly possibilities....

Please be careful!

I used them for the photos.
I have a proper 2 tonne quick lift + stands. - which aren't seen in the pics [thumbup]

[Ocean Racer]

Did you put on the R steering stop bracket with the calipers?

http://www.v70r.com/forums/uploads/1267793615/gallery_1685_289_222125.jpg

I have removed this bracket and rebolted the front calipers back in with shorter bolts.
Yes - as expected they started to eat into the Lower Control Arms. :o

Apart from being a steering stop bracket, what other function do they serve and why did I need them?

[ifnt420]

Apart from being a steering stop bracket, what other function do they serve and why did I need them?

One thing I did find out is that it helps reduce the noises of the calipers (Same as the dampeners), but other than that its just unsprung weight... so lose it like a skirt! [thumbup]

[gridgewell]

What did this end up costing you?

[Ocean Racer]

What did this end up costing you?

Over $2k and lots of beer. [pico]

[n00bkiller944]

Hey Ocean Racer is your back end stock ride height or what?

[Ocean Racer]

Hey Ocean Racer is your back end stock ride height or what?

yes :(
fronts no.

New springs going in very soon

[n00bkiller944]

Why do you have the rear spring as stock ride height?

[06ORXC]

Quick question,

After cutting rear shields, I assume the e-brake is still fully functional, right?

thanks