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XC90 Brake Pads gone Brake Fluid leaking out

A mid-size luxury crossover SUV, the Volvo XC90 made its debut in 2002 at the Detroit Motor Show. Recognized for its safety, practicality, and comfort, the XC90 is a popular vehicle around the world. The XC90 proved to be very popular, and very good for Volvo's sales numbers, since its introduction in model year 2003 (North America). P2 platform.
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TwoVolvos
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Joined: 15 April 2016
Year and Model: '06 XC90 & '04 S60
Location: Colorado

XC90 Brake Pads gone Brake Fluid leaking out

Post by TwoVolvos »

I know I needed to change the rear brake pads on my 2006 XC90 FWD. I was waiting to get rotors and pads in the mail from IPD.

While driving down our small main street I heard something metal fall off the car. The pads were gone, and making a terrible screeching racket. I think it was the metal retaining clip on the rotors w/no pad material left. Somehow one of the retaining clips on the pads actually fell off the car after no pad material was left.

Rotors and pads still not here in mail. Today, I got a warning light that said the car was low on Brake Fluid. There was brake fluid on the wheel and in our driveway, on the drivers side rear wheel.

With no pad material left, is it possible the cylinders pushed out "too far" and brake fluid was being expunged from the lines? Did I likely damage the brake calipers?

Can someone point me through to a walkthrough (with pics) of replacing the pads/rotors on an XC90? Thanks.

If someone has a walkthrough for calipers, I might need that too.

Very frustrated, the timing of getting the parts was such a train wreck. Should have ordered these a week earlier. I think I for sure ruined the rotors, when I was probably going to not have to replace them.

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oragex
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Post by oragex »

If it's the cylinder, perhaps it will need the inner seal replaced, along with the outer dust seal. If the rotor is scorched, it might be hard to remove it because the handbrake shoes stick to it inside. The rear brake bleeder is usually very stuck, order a new one already and spray days in advance with a real penetrating oil. Don't over force or it will cost a new brake caliper. By no means do not put back the old bleeder :wink:

You may have to bleed all four calipers if the fluid in the reservoir has got too low (if the pedal goes too low when braking)

While there, I'd have a look at the brake flexible line on all four wheels. These tend to crack at the bottom and will leave you without brakes while driving (happened to me) :oops:

cn90
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Post by cn90 »

I wrote a Rear Brake-Parking Brake in my 2005 XC90. Ground the car, don't drive it.
Make sure you replace the rotor and parking shoes too!

https://www.matthewsvolvosite.com/forums ... hp?t=73074


Now, if your piston is protruded outward, you may be able to push it back in.
I don't have a DIY for XC90 but I did the brake caliper overhaul in my 1998 S70, detail below.
You have 3 options:
1. If the seal and the boot is OK, you may be able to push the piston back inside.
2. Rebuilt caliper from NAPA etc.
3. Rebuild the caliper yourself using rebuild kit (search online).

https://www.matthewsvolvosite.com/forums ... hp?t=37721
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

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oragex
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Post by oragex »

Just a tip, I also had the piston coming off the seal (when I was replacing the brakes), to push it back (assuming the bleeder is open) it helps to twist it a little while pushing it back. Sometimes it won't pass the lip of the seal otherwise.

cork5695
Posts: 2
Joined: 17 May 2016
Year and Model: 2009 XC90
Location: Pennsylvania

Post by cork5695 »

Trying to replace rear rotor, emergence brake stuck. tight.

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