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Rear Brake Line Flaring

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

polskamafia mjl
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polskamafia mjl

Rear Brake Line Flaring

Post by polskamafia mjl » Sun Dec 01, 2019 3:52 pm

I'm trying to replace the rear passenger side caliper on my 850 but I've rounded off the brake line nut at the caliper. I would like to cut the existing hard line, replace the caliper, and splice in a new section of hardline. From what I've read the hardlines are 3/16 inch or 4.75 mm.

When I brought my new caliper to the auto parts store I couldn't find a flare nut fitting that would screw into the caliper. Does anyone know what thread the hole in the caliper is? I've also read that the P80's use a bubble flare. Does that mean that the new hard line needs to have a bubble flare at the end that connects to the caliper? Autozone and NAPA only have hard lines with 'standard' flares. Is that going to cause sealing issues at the caliper end?

My other question is about connecting the new hard line to the old one. Do I need a double union flare for that?

Any other tips or tricks are also greatly appreciated.

Thanks!


'All my money is gone and I have an old Volvo.' - Bamse's Turbo Underpants

Current: 1995 Volvo 850 T-5R Manual - Bringing it back from the brink of death
Previous: 1996 Volvo 850 GLT - Totaled

xHeart
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Re: Rear Brake Line Flaring

Post by xHeart » Sun Dec 01, 2019 4:05 pm

cn90 is your man. Meanwhile, see this diagram for conversation: https://parts.volvocarslisle.com/a/Volv ... 67887.html

Image


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Past: German Shepherd | 1989 Volvo 740 GL | 1979 Volvo 240

cn90
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Re: Rear Brake Line Flaring

Post by cn90 » Sun Dec 01, 2019 4:08 pm

BMW and Volvo use bubble flare... 4.75 mm line.

I just did the brake line on my 2006 BMW X5. I wrote a detailed DIY for my BMW below.

HTH...

https://www.bimmerfest.com/forums/showt ... ?t=1350813


2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

cn90
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Re: Rear Brake Line Flaring

Post by cn90 » Sun Dec 01, 2019 4:13 pm

Also, with the car this old, consider replacing the rubber hose above the Delta Link "while there"...


2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

polskamafia mjl
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polskamafia mjl

Re: Rear Brake Line Flaring

Post by polskamafia mjl » Sun Dec 01, 2019 4:33 pm

There's a lot of good information in your Bimmer write up. That will be very helpful.

Does anyone know about the flare nut that connects the hard line to the caliper? That's my main hang up at the moment.


'All my money is gone and I have an old Volvo.' - Bamse's Turbo Underpants

Current: 1995 Volvo 850 T-5R Manual - Bringing it back from the brink of death
Previous: 1996 Volvo 850 GLT - Totaled

cn90
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Re: Rear Brake Line Flaring

Post by cn90 » Sun Dec 01, 2019 4:55 pm

Making flare in situ is a big pain.
Things can go wrong all the time (metal tubing not clamped properly and slides, creating bad flare).

If you want avoid making flare, the buy an ATE caliper seal rebuild kit for $10-$15 and rebuild the caliper in situ. I posted a detailed DIY brake caliper rebuild about 8-10 yrs ago in forum...


2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

xHeart
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Re: Rear Brake Line Flaring

Post by xHeart » Sun Dec 01, 2019 4:59 pm

Brake line end-to-end uses M10 x 1.0mm.


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Past: German Shepherd | 1989 Volvo 740 GL | 1979 Volvo 240

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Re: Rear Brake Line Flaring

Post by cn90 » Sun Dec 01, 2019 4:59 pm

Mafia,

The flare but is metric, exactly like I mentioned in the BMW write-up. Just buy a short section of metal line, cut it and now you have 2 flare nuts.

I called these "bolts" in the BMW write-up...bc it looks like a bolt...


2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

polskamafia mjl
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polskamafia mjl

Re: Rear Brake Line Flaring

Post by polskamafia mjl » Sun Dec 01, 2019 5:09 pm

xHeart wrote:
Sun Dec 01, 2019 4:59 pm
Brake line end-to-end uses M10 x 1.0mm.
Thanks. I had seen those specs on a different forum but when I tried an M10 X1.0 thread checker at the store it felt very loose. Is that normal? Another forum had the thread listed as 3/16 inch British Thread but I have no idea what to make of that.

@ cn90

I see that your BMW write up does mention the M10 X1.0 bolts but I have no way of knowing if those bolts are the same on the 850's.


'All my money is gone and I have an old Volvo.' - Bamse's Turbo Underpants

Current: 1995 Volvo 850 T-5R Manual - Bringing it back from the brink of death
Previous: 1996 Volvo 850 GLT - Totaled

xHeart
Posts: 2521
Joined: Sat Dec 03, 2011 8:05 am
Year and Model: 1997 854 NA
Location: Great Lakes - USA
Has thanked: 18 times
Been thanked: 27 times
United States of America
xHeart

Re: Rear Brake Line Flaring

Post by xHeart » Sun Dec 01, 2019 5:40 pm

polskamafia mjl wrote:
Sun Dec 01, 2019 5:09 pm
xHeart wrote:
Sun Dec 01, 2019 4:59 pm
Brake line end-to-end uses M10 x 1.0mm.
Thanks. I had seen those specs on a different forum but when I tried an M10 X1.0 thread checker at the store it felt very loose. Is that normal? Another forum had the thread listed as 3/16 inch British Thread but I have no idea what to make of that.
3/16 in (0.1875) = 4.75mm, refers to copper/steel line size.
All fasteners, male/female, use M10 x 1.0


--
Golden Retriever | 2014D VIDA DiCE | 2013A XC90 +140mi/225km | 2001 V70XC 1st Owner +190mi/ +305km | 1997 Volvo 850 NA 1st Owner +180mi/ +289km
Past: German Shepherd | 1989 Volvo 740 GL | 1979 Volvo 240

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