Help! Problems doing brake job

Wolverine Fan · Post by **Wolverine Fan** » 18 Nov 2006, 13:00

I'm right in the middle of my first brake job on my '94 850 and have been following the instructions on Volvospeed.com to the letter. Everything has gone very smoothly until the time to put it all back together.

The calipers have been collapsed back in and new pads put on, but there is no clearance with the new pads to put the caliper back on over the rotor.

Is there a trick to this? The new pads are the same size, but there is not enough clearance to get them over the new rotor. How thick are the new pads supposed to be? I'm stuck.

Post by **MadeInJapan** » 18 Nov 2006, 13:15

Can you not compress them further? What kind of pads did you buy? New rotors?

Wolverine Fan · Post by **Wolverine Fan** » 18 Nov 2006, 13:30

Yes, new rotors. The pads are PBR Deluxe Plus Organic. Just to see if I was sent the wrong ones I went to a local parts store and compared them with the ones they had in stock. Exact same size and thickness.

After looking at it further, the outboard caliper has collapsed completely, but the inboard side appears to be stuck. I used channel locks to push in the outboard side, but the inboard side will not budge. Should I spray some PB Blaster to see if it will loosen up?

Thanks much for the help.

cocka · Post by **cocka** » 18 Nov 2006, 14:10

Try opening the bleed nipple when compressing the caliper, the system might need a flush out as well to get rid of the sludge that builds up in the system, how many kms etc, has it done. Other than that you may need to rebuild the calipers or at the worst replace them with new ones (ouch).

Post by **MadeInJapan** » 18 Nov 2006, 14:42

cocka is correct. Opening the nipple will help. The reason you can't fit your calipers over your rotors without further collapsing them is because your new rotors are thicker than your old ones which were worn down.

Wolverine Fan · Post by **Wolverine Fan** » 18 Nov 2006, 14:50

Thanks guys, can you describe where the bleed nipple is, or what it looks like?

Post by **MadeInJapan** » 18 Nov 2006, 15:01

It's right next to where the brake line comes into the caliper...looks like a nipple...you can't miss it. Just turn it counter-clockwise to open it. If you open it however, you should go ahead and bleed the brake line...should do that anyway when changing brakes.

CarVolvo · Post by **CarVolvo** » 18 Nov 2006, 15:04

the nipple... looks like .. a nipple... rounded protuding from a hex bolt found on the edge of the unit. Its usually silver in colour. Look on the outside shell of the caliper and you will notice it.

THe bleeder valve is another name for it .. if you remove it you will actually relieve the pressure in the caliper piston.

The piston should settle into the oriface to the point its flush. THis way you could most likely fit them back over the rotor.

Wolverine Fan · Post by **Wolverine Fan** » 18 Nov 2006, 15:30

Thanks guys very much for the responses. I found it but the problem is it is rusted shut and won't budge. I'll spray some lubricant on it, let it sit and try again.
Will let you know.
Thanks again.

Post by **MadeInJapan** » 18 Nov 2006, 15:34

WD-40 probably won't loosen it. If you can get a can of PB Blaster (autozone, pepboys, etc.), get it and use it...let it sit for several hours, if that doesn't do it, then spray it again and let it sit over night. It should come off then.