Volvo s60 T5 rust problems- anybody experienced similar?

loman · Post by **loman** » 08 Sep 2004, 20:55

In November 2003 I bought a new s60 T5. After two months, I started experienceing problems- where when I put the car in reverse or drive, it would not move. I would have to press down on the accelarator very hard. I would then hear a pop sound and only then would the car move. I took it to the dealer and was told that it was a gear box problem and it was replaced. After three weeks, the problems reappeared. Again, I was told it was the gear box and it was replaced. Afetr further three weeks, the same problem. this time they figured that rust was forming around the brake pads. They did some work on the car but I refused to take it back. After negotiations, it was replaced (with some cost to me). However afetr having the car for only ten days, the same problems have started. Their explanation that humidity or water cause the rust to form thereby locking the brakes from being released. Given that we live in a humid climate and the car needs to be washed from time to time, how can a car be manufactured to such specifications?Has any Volvo owner ever experienced this problem?

Dryflyfortrout · Post by **Dryflyfortrout** » 10 Sep 2004, 13:04

Loman - my 2001 S60 has 108000 miles on it without a single problem. Maybe others on this board can offer suggestions, otherwise I would take it up the chain with Volvo.

Post by **matthew1** » 10 Sep 2004, 15:36

That is one of the weirdest problems I've ever read about.

I would think that as the pads wore down the problem would go away, i.e.: the pads<-->rotor gap would increase.

kombi · Post by **kombi** » 17 Feb 2005, 11:22

After only 4 months and 5000 miles I parked my 2004 S60 for 12 days on vacation and the brakes froze up with rust. It did pop free with a little gas but then had thumping every time I stepped on the brakes. When I took it to the dealer, they wanted $980 for all new brake pads and rotors. With a little convincing they called Volvo an authorized it as warranty work... this time. They say they won't cover it if it happens again.

Guest · Post by **Guest** » 16 Apr 2005, 02:45

I have exactly the same problem, 5000km on the clock and brakes that vibrate the car so hard it is embarassing (and not a little worrying) when braking hard from anything over 100 kph. Apparently, it is a known problem, which would suggest Volvo needs to do something urgently about their suppliers.

Yesterday, when I showed the dealer that the discs (made of steel) were now (some two weeks after the problem started) practically free of rust, but the vibration was still present, he agreed to take it for a test drive. When he came back, he immediately agreed to change discs and pads (at the rear where he thinks the problem is) under warranty.

And there is no way on earth Volvo (or anyone else for that matter) could convince a court that they are only obliged to do it once. On the contrary, once Volvo admits there is a problem with rust on the brake discs (and they do this implictly by agreeing to change them) Volvo HAS to do it again, if the same problem occurs. And we should not forget that brakes are top of the safety list, so Volvo is asking for serious trouble both in the courtroom and in the market place if it refuses to respond to customer or media concerns (even outside of the warranty period) and any accident can subsequently be traced back to the brake performance, or lack thereof..

So keep the posts coming...

procky-2oo4 · Post by **procky-2oo4** » 01 Jun 2011, 08:07

I have a 2004 V70. I left the car outside parked for 7 days with the parking brake on. And when I went to drive it the brakes were locked up. It finally broke loose after shifting in and out of gear. It also thumped. I than removed the wheels and lubricated the pistons and calipers. That seemed to fix the problem.

BobbyC · Post by **BobbyC** » 03 Jun 2011, 23:28

Dryflyfortrout wrote:Loman - my 2001 S60 has 108000 miles on it without a single problem. Maybe others on this board can offer suggestions, otherwise I would take it up the chain with Volvo.

Off topic, but I have to comment-

Last summer I bought my nephew's 2001 S60 T5 (he bought it new) w/ 104k on it on which he had spent $16,500 in maintenance since new (combination of dealer and independent service, plus some DIY I helped him with). Every major part on the car (including the transmission), except the engine, has been replaced I think.

Since I bought it, I've replaced both axle half shafts, and both front hub bearings, coil packs (2nd time), the brake diaphragm position sensor, and two days ago the ETM was replaced (thankfully under warranty).

I guess there's something to the "Monday" car vs. the mid-week car and reliability.

Bob

Post by **JRL** » 04 Jun 2011, 05:57

This is a VERY common Volvo issue, a Monday or Friday car has nothing to do with it
Take care with the E brakes
After you wash the car NEVER put them on until they're dry or the car has been driven and the rust burned off
Ever notice a brake disc after you wash it (any car) they will turn to an immediate rust film on them, that needs to be burned off ASAP before real rust forms
Also on earlier cars the cables rust, (and lock up) when that happens they need to be replaced, not the cheapest of jobs
The E brake shoes can delaminate when they get older and when that happens it can jam and lock up the car (which is what happened to you)