2013A XC90 - Brake Line, Hose, Caliper and Rotor Service Topic is solved

[xHeart]

It is time, I've collected all the replacement parts for the front brake service. Here is a discussion that helped me move on this task. What Size are my Rotors: viewtopic.php?t=93783.




I like CN90's suggestion of surgically removing the flex hose so the flare connection is saved and reused. Here is why, 2001 V70XC - Brake line and Caliper Service: viewtopic.php?t=91484.

What is your take on surgically removing...

[chitownV]

Have you tried to break free your brake hoses using a flared wrench first? Ensure you have good ones. With the cheapo flared wrenches, I was only able to get a few uses before they started to widen up. I would try soaking with some PB Blaster, even using a little mild heat. Funny thing, I once used a torch lighter (bought at a gas station, lol) to heat a brake hose fitting and that little amount of heat was all it need to break it loose. Another time I did use the torch with the bleeder screw open on 25 year old hoses. I wouldn't suggest taking a cutting wheel to it until that's the very last resort and it looks like you've done that before in the '01 V70XC. With your XC90 being a dozen years newer, maybe it's not as bad. I drive through winter salt and could still get my XC90 brake hoses loose without a cutting wheel or heat.

Depending on your mileage, if your hoses already need changing, your calipers may need to be replaced as well, especially if you drive through winter salt. They are affordable now at Rockauto (find an online 5% off), or go to Autozone online (find a 20% off coupon). As a 2013 XC90, I am assuming you have the 328mm calipers. You could buy reman 328mm or go for the 336mm, change calipers w/ brackets, then paint them ahead of time. The reman calipers will also ensure you don't encounter a seized bleeder screw issue, the piston seal will be newer, and the rubber bushings will be newer.

This makes for a much smoother job as the caliper & hose can be assembled ahead of time and installed along with the other components. Then the very last thing you need to do is just unscrew the old hose and screw on the new hose (test the old hose breaks free as a first step before replacing the brakes). I lost minimal fluid doing it this way too.

My painted calipers still look good using POR15's caliper paint. My braking also improved more than I would have guessed by replacing old calipers. They must have corroded and/or pitted on the inside, not making the piston move that well, and the brackets had some groove wear where the brake pad ears sit, affecting smooth movement.

Good luck.

[xHeart]

Have you tried to break free your brake hoses using a flared wrench first? Ensure you have good ones. With the cheapo flared wrenches, I was only able to get a few uses before they started to widen up. I would try soaking with some PB Blaster, even using a little mild heat. Funny thing, I once used a torch lighter (bought at a gas station, lol) to heat a brake hose fitting and that little amount of heat was all it need to break it loose. Another time I did use the torch with the bleeder screw open on 25 year old hoses. I wouldn't suggest taking a cutting wheel to it until that's the very last resort and it looks like you've done that before in the '01 V70XC. With your XC90 being a dozen years newer, maybe it's not as bad. I drive through winter salt and could still get my XC90 brake hoses loose without a cutting wheel or heat.

Depending on your mileage, if your hoses already need changing, your calipers may need to be replaced as well, especially if you drive through winter salt. They are affordable now at Rockauto (find an online 5% off), or go to Autozone online (find a 20% off coupon). As a 2013 XC90, I am assuming you have the 328mm calipers. You could buy reman 328mm or go for the 336mm, change calipers w/ brackets, then paint them ahead of time. The reman calipers will also ensure you don't encounter a seized bleeder screw issue, the piston seal will be newer, and the rubber bushings will be newer.

This makes for a much smoother job as the caliper & hose can be assembled ahead of time and installed along with the other components. Then the very last thing you need to do is just unscrew the old hose and screw on the new hose (test the old hose breaks free as a first step before replacing the brakes). I lost minimal fluid doing it this way too.

My painted calipers still look good using POR15's caliper paint. My braking also improved more than I would have guessed by replacing old calipers. They must have corroded and/or pitted on the inside, not making the piston move that well, and the brackets had some groove wear where the brake pad ears sit, affecting smooth movement.

Good luck.

YES, they do!
I've wire brushed all hose connections and treated with PB blaster for overnight; counted my tools for this job, except the hex socket for caliper guide pin is neither 10mm, 3/8" - too big to seat, nor 8mm - too small to catch. It looks hex unless I am missing something.

[chitownV]

Awesome, they are freeee! Lol. Have you tried 9mm hex? Do you have a set of torx bits?

I don’t even remember what the size is as I have between 7-9mm hex that I shortened with a belt sander. Oh, I also have a couple half sizes in that range too. Shortening the bits help with clearance issues, especially with the rear calipers.

Nowadays, with how old these XC90s are, the high miles, and repairs being done by different shops & owners, I won’t assume what’s there or the size. You can try using your phone to take a pic of the guide pins….or unbolt the carrier and caliper as one unit. That way you can get a good view on the guide pins while using your tools.

[Krons]

My braking also improved more than I would have guessed by replacing old calipers. They must have corroded and/or pitted on the inside, not making the piston move that well, and the brackets had some groove wear where the brake pad ears sit, affecting smooth movement.

Was rotating tires after an oil change on the kids 05 XC90 2.5T (196k miles). While there thought I’d flush the brake fluid. All went well but didn’t gain much improvement in pedal feel like I did on my 08 S60.

Parking brake is non-functional and certain it’s the mechanism in the rear rotors locked up as I’ve messed with the cables in the console to no avail. I’ll tackle that another day when I have more time.

[chitownV]

My braking also improved more than I would have guessed by replacing old calipers. They must have corroded and/or pitted on the inside, not making the piston move that well, and the brackets had some groove wear where the brake pad ears sit, affecting smooth movement.

Was rotating tires after an oil change on the kids 05 XC90 2.5T (196k miles). While there thought I’d flush the brake fluid. All went well but didn’t gain much improvement in pedal feel like I did on my 08 S60.

Parking brake is non-functional and certain it’s the mechanism in the rear rotors locked up as I’ve messed with the cables in the console to no avail. I’ll tackle that another day when I have more time.

It’s possible you might need front calipers and/or hoses. My guess is the dissimilar metals of the caliper slowly contributing to corrosion inside the caliper. Also, inspect the caliper bracket for wear.

I did have a rear caliper seize and had to replace it, but that’s all cast iron (minus the piston, bleed screw, & hose).

[xHeart]

Awesome, they are freeee! Lol. Have you tried 9mm hex? Do you have a set of torx bits?

I don’t even remember what the size is as I have between 7-9mm hex that I shortened with a belt sander. Oh, I also have a couple half sizes in that range too. Shortening the bits help with clearance issues, especially with the rear calipers.

Nowadays, with how old these XC90s are, the high miles, and repairs being done by different shops & owners, I won’t assume what’s there or the size. You can try using your phone to take a pic of the guide pins….or unbolt the carrier and caliper as one unit. That way you can get a good view on the guide pins while using your tools.

Yes, concur.
The guide pin is indeed hex; now the size between 10mm, 3/8" and 8mm is either 9mm or 5/16". I do not see 9mm at the nearby stores, but 5/16" is available at local O'Reilly's.

I am leaning to replace flex hoses, calipers, and 328mm rotors. Is a depressed brake pedal only method for preventing brake fluid fluid escape while disconnecting flex line?

[chitownV]

Try Home Depot too or order from Amazon. I’ve bought a set from Amazon before to ensure it had all the metric hex sizes.

The fluid will gravity drip since the brake reservoir is at a higher level. You have to cover/plug the line or work quickly.

If you do buy new calipers, paint them. The zinc coatings don’t prevent rust and in pics on Rockauto, you can already see rust poking through. I used POR15 caliper paint because it’s a harder paint. Allow it to dry/cure for at least 48hrs.

With dual pistons, it might be a good idea to replace the calipers to ensure they both are more balanced in their movement. Remember to bench prime calipers by opening the bleed screw, pour some brake fluid in the hole for the hose, and move, rotate, circle, figure 8s, cha cha…so the fluid can work around the inside of both pistons.

You can try to find good brake pads too that have a higher friction rating: https://www.swedespeed.com/threads/chit ... st-7913072

Good luck.

[xHeart]

The passenger side could soon be bare knuckle; tempted to freshen up spindle with new ball joint and hub assembly.
The 15mm flex hose connection at the caliper has turned, yea! 13mm at the flare coming later today.
The caliper guid pin is 9mm hex.

[xHeart]

With dual pistons, it might be a good idea to replace the calipers to ensure they both are more balanced in their movement. Remember to bench prime calipers by opening the bleed screw, pour some brake fluid in the hole for the hose, and move, rotate, circle, figure 8s, cha cha…so the fluid can work around the inside of both pistons.

Slow progress but with satisfaction...
Using brown paper bag for barrier - 2 coats of VHT Gloss Black Epoxy with 10sec between the coats; and dries to touch in 30 minutes.

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