brake booster replacement

TJMAS · Post by **TJMAS** » 11 Feb 2011, 08:43

Looks like time to replace the brake booster on my 03 xc90, T6. I have a constant air leaking inside from the cylinder. Question is does anyone have the volvo procedure for this and are there any special tools needed. I had read a generic article about this and it said something about having to adjust the rod. Any help would be great.

TJMAS · Post by **TJMAS** » 11 Feb 2011, 08:44

Does anyone make a after market for this vehicle?

Post by **jimmy57** » 11 Feb 2011, 20:00

The brake booster on that vehicle is a special booster. It has an Active Brake Booster which means it has an electric solenoid so the brake pedal can be applied by ABS module when DSTC or RSC needs high brake force. The push rod will not need to be adjusted usually. Have you tried Erie Vo-Vo?

TJMAS · Post by **TJMAS** » 11 Feb 2011, 21:25

Yes I found some used on the erie site. I also found remanufactured by cardone, have you heard of any problems with these? Very reasonably priced.

Post by **jimmy57** » 11 Feb 2011, 21:52

I have used Cardone components on domestic cars and trucks and have no problems. I looked at their website and was surprised at the coverage for apply solenoid brake boosters.

Post by **gshadow325** » 12 Feb 2011, 05:21

i will chime in since i just did this about 1000miles ago on my T6

Autozone A1-Cardone New Rebuilt/Remanufactured 53-3115 $185 wholesale price plus $65 core
Erie Vovo - Used with lifetime warranty $175

I went new/rebuilt because i was able to get it same day.

Removal is not as smooth as a inline 5 cylinder engine. Took me 2hrs to get it out and 1/2 to get it back in LOL
I took out the airbox, moved the fusebox, unbolted the turbo tubes, removed the strut bar, un bolted the abs unit under the booster. inside was easy 4 bolts, one clip.

After the unit was out. Upon inspecting why the old one failed, i noticed if i just changed the solenoid it would have been fine. unfortunatly in the good ole US of A. it is illegal to sell just the solenoid. the unit must be sold as one complete unit.

Since it was my first booster, it took a while to do. Since i did not want to pay $250-300 for the labor.

Hindsight: Get a used one with a lifetime warranty from Adam @ erievovo. WHY? You know you will get the right part and they will inspect it and send you the proper part. Autozone didnt send me the wrong one, i know they could have since all s60 and v70's from 2001 and newer share the same item BUT our XC90 has its own part number and it is indeed different than all the others. Plus, i dont trust autozone/pep boys/advance auto parts ect. its just too much work to redo it if it was the wrong one.

Also, make sure rotors and pads are ok. I did this at 149,875 miles today i have 151,233miles. I was wondering if i did something wrong in the past 1000 miles but turns out my front and rear rotors were thin on top of 35% left on the rear pads. so i did new front and rear aftermarket rotors and new front and rear OEM pads(rotors $118 pads $105). i also did stainless steel lines too. Now my brakes are very twitchy/sensitive

they stop alot better than before.

Now i am happy i have brakes that are similar in feel to my C70 that has 6 piston wilwoods. Said similar, not the same as LoL....Good Luck, and its not that horrible of a job, you can do it over a weekend to take your time. 3-4hrs for the first one, 2 hrs for the second one

TJMAS · Post by **TJMAS** » 12 Feb 2011, 08:13

I had found the rebuilt at advance auto parts for $165.00 plus $65 core. I was afraid that getting the used my be a issue later due to it seeming to be a common problem on the xc90's. I know it lifetime gauranted but I don't want to have to do it again. I spend way to much time working on this car. The common part # I get from multiple sites seems to be 533115, I presume it's the right one but how to be sure.

Post by **gshadow325** » 12 Feb 2011, 20:19

TJMAS wrote:I had found the rebuilt at advance auto parts for $165.00 plus $65 core. I was afraid that getting the used my be a issue later due to it seeming to be a common problem on the xc90's. I know it lifetime gauranted but I don't want to have to do it again. I spend way to much time working on this car. The common part # I get from multiple sites seems to be 533115, I presume it's the right one but how to be sure.

order it from autozone and its free shipping to the store and you can return the core to the store. cheaper in the long run.

Honestly, get the used one from erievovo. even though it is used, i dont trust the reman cardone units. mexico refurbs, and iffy quality scares me. if i had to do it over again i'd get the erievovo used unit.

TJMAS · Post by **TJMAS** » 17 Feb 2011, 20:43

had looked at getting the fuse box loosened up to move out of the way one other time without success. What all holds it in place?

Post by **gshadow325** » 19 Feb 2011, 05:26

oh yeah fuse box comes out. take off the battery terminal and it is obvious from there.