S40 (New) Brakes : The big brake job!

[StatusRed]

Just thought I'd give a little writeup of the big brake job I've just finished.

Tasks & parts:

• Install painted and decaled brake calipers all round [OEM]
• Install new rear pads [Brembo] (old ones were wearing unevenly)
• Install new front discs [Mintex] (needed to pass MoT)
• Install new front pads [Brembo] (needed to pass MoT)
• Install braided steel brake lines all round [Goodridge]
• Bleed the brakes and clutch [Castrol React Performance Dot 4 + Gunson Eezibleed]

Unlike last year when I installed new rear discs and pads this time round I did much more research to have everything I needed ready so I wasn't met with any surprises.. Some parts of the job did take longer than expected but nothing stopped my progress.

Goodridge brake line review:
I paid a bit extra to get Goodridge brake lines instead of HEL or Black Diamond, I had read that the lines were an "exact OEM replacement"; but I wouldn't say that is strictly true. Everything fit together but the fitment to the rigid brake line worked in a different way and meant that it wasn't secured correctly in the bracket. I used cable ties to make sure it wasn't floating around and would make a noise when driving. I also found the rubber mounting bits extremely difficult to get to fit into place. If I were to install steel brake lines on a future car I'd give the other manufacturers a go.

Bleeding the clutch:
From my other thread asking about how to bleed the clutch there seemed to be some confusion as to whether it could be done with a one man bleeding kit (i.e. Gunson Eezibleed) or not. I managed to bleed the clutch using the one man kit without any issues, on my car there is no bleed nipple screw, instead you turn it by hand. I was surprised at the amount of dirt coming out (see the attachments)!

Overall I'm pleased with the job but it was a full day's work all in all. I've taken the car out for a drive and the brakes and clutch seem to be working fine with no leaks or messages on the dashboard about low brake fluid etc..

If anyone is interested in doing any of this for yourself and has questions feel free to ask!

[domhart10]

Nice job Calipers look good

[canis]

Well done. I was wondering how you were getting on with this. Glad it all worked out.

[LizardOfBodom]

Those calipers looks deadly indeed - how did you do them? (decaling + what kind of paint?) I plan to do that one day myself (but probably in grey).

[StatusRed]

Originally Posted by domhart10

Nice job Calipers look good

Originally Posted by canis

Well done. I was wondering how you were getting on with this. Glad it all worked out.

Cheers guys

Originally Posted by LizardOfBodom

Those calipers looks deadly indeed - how did you do them? (decaling + what kind of paint?) I plan to do that one day myself (but probably in grey).

Haha thanks.

The first thing was getting them really, really clean, that's why I bought a second hand set and painted them off the car as it was far easier to clean and paint them. It involved wire brushes, sand paper, white spirit, lots of brake cleaner and isopropyl alcohol.

I used the e-tech brake caliper paint kit and did about 3 coats on the visible parts of the calipers and 2 coats on the back side (really didn't need to paint the back side but thought I might as well to help protect against rust etc..).

Once that had dried for 24 hours I then put on the decal which was a high temperature laser cut vinyl sticker. It's already aligned on the applicator sheet for you, you just need to stick it down in the right place. I then put two coats of clear lacquer over the decal (I have yet to see how it's going to weather, but this was same process based on someone here's (possible paddy or heyskull?) advice and they have had painted and decaled calipers for years).

Make sure you don't paint anywhere that the brake pads slide along.. I painted an area on the front caliper carriers and later had to sand it off when I found that the brake pads wouldn't slide freely.

[LizardOfBodom]

Ah cool, thanks for info.
Painting it off the car is defo the way to go, just extra cost of second set or dismantling current ones is a bummer. Great idea with this decal, looks really nice, my only concern is if it stay with all caliper heating up and all elements?

[cheshired5]

Originally Posted by StatusRed

Make sure you don't paint anywhere that the brake pads slide along.. I painted an area on the front caliper carriers and later had to sand it off when I found that the brake pads wouldn't slide freely.

I put police/XC90 brakes on my S60 and refurbished them first.

Painting the caliper and carrier is fine as long as you don't go crazy and affect the profile of where the pads sit.
Some pads are also just not a good fit so I stuck with genuine or ATE who make genuine for my car.
Also use brake grease on pad/caliper/carrier contact points.

Mine was a year ago and all is still perfect.

[StatusRed]

Originally Posted by cheshired5

I put police/XC90 brakes on my S60 and refurbished them first.

Painting the caliper and carrier is fine as long as you don't go crazy and affect the profile of where the pads sit.
Some pads are also just not a good fit so I stuck with genuine or ATE who make genuine for my car.
Also use brake grease on pad/caliper/carrier contact points.

Mine was a year ago and all is still perfect.

Looks awesome

It slid absolutely fine once I had just sanded off where I had painted along where the outer front pad slid in the carrier, it must have just been less than 1mm too thick of paint, just enough for it to catch the pad.

Taking off the old caliper and pads it's almost bizarre that something so dirty was working fine, definitely did not slide freely by hand. I might clean them up, paint them black (without a decal) and sell them on eBay! Loads of paint left.

[StatusRed]

Originally Posted by LizardOfBodom

Ah cool, thanks for info.
Painting it off the car is defo the way to go, just extra cost of second set or dismantling current ones is a bummer. Great idea with this decal, looks really nice, my only concern is if it stay with all caliper heating up and all elements?

I got a second hand set off a forum member who was breaking a 1.6D V50, £50 including postage! I guess though the T5 setup might be rarer and more expensive.

I was recommended a specific decal which is meant to be high temperature and used by an existing forum member who's had it on their car for years without issue, so I'm hoping it stays on!

[x DTR x]

Make sure you spray some clear lacquer over Volvo stickers on calipers to seal them as they will come off with jet wash and general wear and tear. Didn't seal mine at first and they didn't last long. Redid them and still look good after 3 years. Also, wheel cleaner is ok to use to keep them clean but don't use break cleaner on them as it will strip the paint and everything! Hope this helps.