DIY Rear Brake Dust Shield Gasket for FWD p80 v70, S70, 850, etc (PN# 3546275)

[MattaClark]

During a long (and ultimately doomed) restoration of a 1998 v70 GLT (story for another time, or never) I did a complete rear end rebuild and found myself searching in vain for replacement rear brake dust shield gaskets, so I thought I would post my DIY cut files here to make someone else's life easier. Should apply to all p80 FWD models and I believe some of the early (up to 2004?) p2 FWD models.

The rubber brake dust shield gaskets (PN# 3546275) that sit behind the dust shield against the axel stub plates seem to be unobtainium. I tried to order these three times (from FCP, IPD, Volvopartswebstore), and after being told three times that they were either out of stock or three months backordered, I gave up and decided to recreate my own.
After finding Neil(@Scot850)'s 2015 post on the subject, I went down a long rabbit hole of trying to find the appropriate 1/8" or 2-3mm temperature/oil/uv resistant fabric-reinforced closed-cell NDAX or Neoprene/EDPM blend foam for less than $100/sq ft, I admitted defeat and bought a cheap 3' roll of tool box foam for $10.
Unfortunately my existing gaskets were so degraded that I was barely able to selvage half of one to use as a template.

Existing gasket

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So I took some calipers, and after a few iterations I made a pretty close replica as a digital cut file.

A recreation of the original gasket shape.

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After a few tests, I made some revisions to the original shape to add more material around the base of the gasket around where the cut out for the hand brake is to ensure a better seal against dust. Could have just been my weird after market dust shields but the lower half of the original gasket shape seemed pretty useless without this modification. I've added some photos of the back side with improved gasket.

Front of the dust shield, the added material of the modified gasket actually seats behind the opening for the hand brake mechanism.

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View of the backside of the dust shield, the modified gasket shape forms a better seal.

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I've attached a 100% scale .pdf version (this forum has limited file type support, if you want a .dxf or other file type, let me know and I can send one to you), please use it as you like. If you have access to a laser cutter or a cricket, obviously that would give a cleaner result but I went for the quick and dirty option of printing, tracing, and cutting out by hand.

Tracing the new gasket templates on to my gasket material.

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p80 Volvo FWD Rear Brake Dust Shield Gasket Cut File.pdf

.pdf "cut" file for the rear brake dust shield of FWD p80 v70, s70, etc model Volvos

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The rear dust shields themselves (PN# 3516884) were totally rusted through, and as I soon discovered, they are starting to become rare. FCP was out of aftermarket stock at the time, and I opted for the $45 each eBay option over the $90+ Volvo branded ones. As a note of caution, the cheap dust shields I received were slightly different to each other, and neither were as quality as the originals: one came pre-painted was clearly cheaply pressed as it has some rippling in it, the other needed to be modified twice (first to change the mounting hole placements which were .25" off, then to be cut to allow room for the caliper to be mounted). I didn't mind the slightly lower quality and extra hour of arts and crafts, but just remember you get what you pay for, even with seemingly over priced stamped steel.

Cheap dust shield on the passenger side has some wrinkling.

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Cheap dust shield on the driver side needed to be cut and bent back to allow more room for the caliper.

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Driver side dust shield after being modified to fit the caliper.

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Happy wrenching.

[scot850]

I well remember the challenges. As you have probably read, finding many parts for the rear of a P80 AWD can be a challenge. I eventually got the real deal gaskets well after completing the job if I recall. They are still in a box with the spare reconditioned unobtanium rear caliper dust shields.

Sorry to hear that your project did not get completed. That is so frustrating.

Thanks for sharing the info and especially the template.

Neil.

[jmartin919]

Never worked on the back end more than replacing brake pads. Based on the effort required to get to these is it worth it to pull the shields and gasket from a salvage yard?

[MattaClark]

Never worked on the back end more than replacing brake pads. Based on the effort required to get to these is it worth it to pull the shields and gasket from a salvage yard?

Getting the rear dust shields off requires removing the wheel bearing... so you're looking at pulling the wheel-> caliper -> rotor -> hand brake pads-> wheel hub -> 4 small bolts on the dust shield. If you're already in there though, and find a set in good condition, I would definitely take them for your "just for when" pile.
I can't imagine the seals themselves would be in any condition worth salvaging.

[scot850]

Or you do what others do and slice the dust shield at the narrowest point by the caliper and bend it over the hub.

Neil.