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Volvo XC90 Front Brake Job

A reader/member did AN XC90 FRONT BRAKE JOB and documented it for us.
2005 Volvo XC90 (P28 MY05) 2.5 T wagon. Photographed in Lindfield, New South Wales, Australia.
Credit: OSX / Public domain

For an XC90 Front Brake Job, you will need the following:

  • jack and jack stands
  • lug wrench
  • a couple of flathead screwdrivers
  • 7-mm hex tool (got mine at IPD)
  • 18-mm socket and a LONG ratchet or breaker bar
  • 10-mm socket -PB Blaster or something like it
  • brake cleaner
  • brake fluid

MVS Contributor stone36 documents his XC90 front brake job! » 

So I am going to replace the pads and rotors on my XC90. I am pretty excited that they are original and I have 56,000 miles on the car. With that success rate I am really leaning towards full OEM this go around. I usually buy from FCP and IPD and found something interesting, FCP seems to sell OEM pads and aftermarket rotors, and IPD sells OEM rotors and aftermarket pads.

So I am wondering what you all think and if the aftermarket on each of those sites are actually made by the OEM supplier? Is this Volvo’s way of controlling inventory, only offering parts for a job to be sourced from multiple stores?

“So I did my front brakes yesterday, attached is my write up on the process. If anyone has questions let me know, I am happy to revise if this doesn’t make sense.

I also used the Motive pressure bleeder system to flush the brake fluid. It was easy as can be and should be a must-have if you own more than one Volvo since it looks like they all share the same sized reservoir cap.”

2005 volvo brake job

When bleeding I highly recommend alternating fluid colors. I think I wasted fluid because I was replacing the standard off-yellow colored fluid with the same off-yellow fluid. It’s much more of a gradual change (it comes out pretty slow to the back tires) than I figure going to red or blue would be. Other than that it worked great.

By the way, for those of you who are going to read this because you are going to do this job and don’t know if you have 316mm or 336mm, you can read the part number on the rotor without removing the wheel if it is lined up properly. It is stamped on the outside of the rotor (If you think of the rotor being a top hat and laying flat, your part number will be written around the had not on the “brim” if that makes sense.). 30657301=336mm and 30736406=316mm. Mine happen to be 336. Yeah, there’s more material, so those cost more…

There are ads on the top of this page for a bunch of suppliers, I have only used FCP and IPD personally. If you have the big rotors (336 mm) and want to go 100% OEM, you can get the pads from FCP and the Rotors from IPD. I went with both from FCP, which was aftermarket rotors and OEM pads.”

2005 XC90 Front Brakes Replacement Tutorial

Volvo XC90 Front Brake Job

More about the Volvo XC90:

The Volvo XC90 is a mid-size luxury crossover SUV manufactured and marketed by Volvo Cars since 2002 and now in its second generation.

The first generation was introduced at the 2002 North American International Auto Show and used the Volvo P2 platform shared with the first generation Volvo S80 and other large Volvo cars. It was manufactured at Volvo’s Torslandaverken. Volvo moved production equipment of the first generation to China and ended Swedish production at the end of 2014, renaming the car as the Volvo XC Classic (or Volvo XC90 Classic).

At the end of 2014, the second generation XC90 was introduced. It is based on a new global platform, the Scalable Product Architecture (SPA). Both generations of the XC90 have won Motor Trend‘s SUV of the Year award in their debuts.

In January 2001, Volvo débuted its Adventure Concept Car at the North American International Auto Show, to gauge reaction to the styling and features of its upcoming SUV.[8] In November 2001, Volvo released a teaser image showing the frontal styling of the production version, named the XC90. Notable as Volvo’s first SUV model, the styling of the XC90 recalled the concept.[9] In January 2002, the full XC90 unveiling occurred, at the North American International Auto Show.[9] Production began in August 2002, after Volvo’s traditional mid-year shutdown, with the first XC90s coming out of the Torslanda factory in Sweden.[9]

At its North American launch for the 2003 model year, the XC90 was presented with a choice of two trim levels, the 2.5 T and the T6. The 2.5 T was the entry level version and offered a 2.5-litre B5254T2 “T5” turbocharged inline-five engine, producing 208 hp (155 kW) and 236 lb?ft (320 N?m) mated to an Aisin co-developed five-speed AW55-50/51 automatic. The T6 offered a 2.9-litre B6294T twin-turbocharged inline-six with 268 hp (200 kW) and 280 lb?ft (380 N?m) mated to a GM-sourced, Volvo-modified four-speed 4T65EV/GT automatic. While the 2.5T came standard with front-wheel drive, a Haldex Traction all-wheel drive (AWD) system was optional. The T6 was offered only with the AWD system.

Yamaha V8 engine was added in 2005. This 4.4-litre Volvo B8444S engine produced 288 hp (215 kW) for the first few models later upgraded to 311 hp (232 kW) and 325 lb?ft (441 N?m) of torque. Volvo sold just over 40,000 XC90 units in North America that year.[10]

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