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S60 Brakes Stuck occasionally - 2007 S60 2.5T

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive "P2" platform cars.

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VeroS60
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S60 Brakes Stuck occasionally - 2007 S60 2.5T

Post by VeroS60 » Fri Aug 23, 2019 1:15 pm

Hi, I have a 2007 S60 2.5T exhibiting a problem where the brakes sometimes get stuck fast after driving a few miles. It's as if the brake is being applied with no pressure on the brake pedal. This has happened twice now. The fist time I checked the temp of the cailpers and found the RF and LR were much hotter. But after and hour or so they were no longer stuck. Thinking it might be a stuck caliper I check them all and none were stuck - they all moved easily. I cleaned and re-greased everything (pads, carriers, etc.), and the problem did not occur for 5-6 weeks with many trips around town. But today I made a short trip (2 miles) and returned home.l After a few minutes I restarted the car to move it out of the sun and the brakes were stuck fast. I immediately jacked up the rear and found the LR wheel stuck fast whereas the RR wheel turned freely. I jacked up the front and found the RF stuck fast whereas the LF turned freely. I loosened the bolts on the MC and after which he stuck wheels moved freely, however this is inconclusive as it could have had time to release on it's own as before.
So any ideas? Could it be the booster or the master cylinder? Strange way for a part to fail...
Thanks in advance for any ideas on how to address this.
Last edited by matthew1 on Fri Aug 23, 2019 1:18 pm, edited 1 time in total.
Reason: Edited title. Please, no "??"s in titles.



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Re: S60 Brakes Stuck occasionally - 2007 S60 2.5T

Post by oragex » Fri Aug 23, 2019 1:44 pm

I think Volvo doesn't put grease on the caliper sliding pins - just the bare rubber boot. Anyhow, regular grease can cause these pins to seize in there because it causes the rubber boot to swollen (will need replaced)



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Re: S60 Brakes Stuck occasionally - 2007 S60 2.5T

Post by jimmy57 » Fri Aug 23, 2019 1:48 pm

Brake booster is highly suspect. Those calipers are the same circuit at master cylinder. If you can catch it dragging and park on level ground, then you put in neutral and test roll it to see that it has drag. Now loosen the two nuts holding master cylinder to booster only one turn and then repeat the test roll to see if it now moves freely. That will confirm master cylinder. If there was anything done under dahs then it can be brake light switch or even trim around pedal at underdash panel holding faint pressure on pedal. Otherwise it is the booster regulator valve has broken and blocks the full return of the pushrod out of front of booster that pushes into master cylinder.



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Re: S60 Brakes Stuck occasionally - 2007 S60 2.5T

Post by VeroS60 » Fri Aug 23, 2019 4:00 pm

Jimmy57, if exhibiting stuck brakes condition and I loosen the MC bolts, does it I indicate MC or booster is the problem? I’m suspecting booster is the problem as I can’t imagine how an MC could fail in this way. I’m surprised others have not experienced this type of failure. Btw I’m using silicon grease on the pad ears/carriers and on the pins, and yes, not altogether sure any grease should be used on the pins.



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Re: S60 Brakes Stuck occasionally - 2007 S60 2.5T

Post by abscate » Fri Aug 23, 2019 4:00 pm

Ive had three calipers freeze up from cheap aftermarket slide pins made of Chinesium metal, they corrode and jam up. I greased the heck out of them. Details in the P80 forum.


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Re: S60 Brakes Stuck occasionally - 2007 S60 2.5T

Post by jimmy57 » Fri Aug 23, 2019 5:14 pm

It is possible that caliper hardware or bad calipers on the diagonal master cylinder shared circuit both fail at once. I have not seen that but when I have had the booster fail to retract fully it was always those wheels on P2 and some Volvos with frt/rear split it would be front brakes as the front brakes are the back section of master cyl on those. Loosening the master cylinder detects booster problems and if you loosen the nuts a turn at least and it is still not able to be moved on level ground, then it is hardware at the wheel. ABS has individual circuits for each wheel and if the brake fluid were foul then it would be unlikely to stick those two at once. One would likely rust u and the other would be later. Rubber hoses have inner layer failure affects only one wheel as that is a failure at caliper or very close by the caliper. It is also possible to detect booster sticking by loosening the rear brake line but on many models that is hard to do and a swivel socket and long extension gets it loose quick to get the answer quick.
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Re: S60 Brakes Stuck occasionally - 2007 S60 2.5T

Post by chrism » Fri Aug 23, 2019 8:49 pm

If the booster and/or MS were ever replaced the installer may have not have carefully matched the push rod length to the original configuration. I’m not really sure if a too-long rod would cause your problem but it was interesting that loosening the MS helped. I would be inclined to try shortening the rod a couple of turns. Just make sure you you still have plenty of pedal before you go sailing down the highway.



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Re: S60 Brakes Stuck occasionally - 2007 S60 2.5T

Post by jimmy57 » Sat Aug 24, 2019 9:08 am

The fill port is at the rear of bore areas for the pistons in m cyl. The fill port is the holde that feeds brake fluid into the bore from reservoir. The first couple mm travel will put the cup seal on piston past the fill holes and now seals fluid in lines all the way to calipers. When pistons continue forward the pressure builds for brakes. If the pistons do not return all the way to rear then the fill port can't open the passage to reservoir. If the fluid gets heated and expands then you have pressure build enough to apply brakes. The fill ports are not super precise so you can have one circuit stuck brakes or all brakes stuck depending on the exact point the m cyl pistons fail to return to rear stop in the bore. In my experience I have found many more times that the rear piston supplied circuits are the stuck ones.



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Re: S60 Brakes Stuck occasionally - 2007 S60 2.5T

Post by chrism » Sat Aug 24, 2019 12:18 pm

Jimmy57,
So might that add some validity to my theory about the push rod between the booster and the MC? If the rod is too long it would start pushing the piston forward when you snug up the bolts. I always make sure I can mount the MC up to the front face of the booster without feeling the rod pushing the piston forward. I think VeroS60 should measure how far the rod extends past the face of the booster and compare that to how deep the piston pocket is from the mounting face of the MC. Of course you have to also consider the thickness of any spacer that might be sitting between the booster and MC. If it’s a rebuilt MC it might be the piston pocket isn’t as deep as the original.



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Re: S60 Brakes Stuck occasionally - 2007 S60 2.5T

Post by jimmy57 » Sat Aug 24, 2019 2:07 pm

I have installed boosters and had the pushrod problem immediately. The highest failure rates causing this were a few years ago when those club anti-theft gizmos were popular. Pulling up on pedal can break the regulator valve in back of booster. Master cylinders leaking into open boosters will fail them too.



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