Volvo Maintenance Hints for 7xx/9xx - Bill Garland's Nuclear ...

● remove the wheel, replace the lug nuts back on the bolts for a couple of turns (so the top of the bolt
doesn't show through the nut) and tap the head of the nut swinging towards the car. Ddon't use a
hammer on the pad-area rotor. You can medium-tap the circumference of the center portion of the
rotor as you spin it, also. It takes patience (My 1985 BMW 325es rears took me 2 hours). Editor's
note: use a soft-faced mallet.
2. If you DO plan on changing the rotors:
Follow the steps above, but with increasing force. If it is STILL stuck, crawl under the car (which must
be properly on jack stands), face outward and spin the rotor while WAILING on the outside edge of the
rotor with a mallet/hammer (outwards). It WILL eventually come loose.
Just try not to have any part of your body under the rotor when it pops off (usually you can tell it's about to
go). Editor's note: use a thin coat of anti-seize on mating surfaces between hub and rotor to easy later
disassembly.
Brake Rotor Installation Techniques to Minimize Pulsation.
[Editor's Note] Per the Volvo manual, match the balance mark on the rotor (a short line at one spot on the
hub portion of the rotor) with the balance mark on the hub, a short line on the shoulder of the hub bearing
cover. Look closely through the rust: it's there! This matches the rotor and hub and minimizes runout. Make
sure you have removed all rust from the portion of the hub that contacts the rotor.
[Tech Tip from Wagner Brake] If the balance lines are not present or are invisible when replacing or
removing the rotor, refer to the following service procedure to minimizes hub/rotor "stacked" runout:
1. Completely clean the hub area contacting the new/turned rotor.
2. Install the rotor on the hub, securing it with at least three lug nuts tightened to 20 lb. ft. (27 N-m) for
testing.
3. Using a dial indicator, determine the total runout of the system. The total rotor and hub runout must not
exceed .002" (.05mm).
4. If the runout exceeds .002", proceed as follows:
❍ Remove the rotor and rotate it clockwise until the next hole lines up with a stud;
❍ Secure the rotor in the new position, reindexed as described in Step 2; and
❍ Repeat the checking and rotation (reindexing process) until the system measures .002" or less
total runout.
5. If .002" (.05mm) or less runout cannot be reached, the hub should be replaced and Steps 2 through 4
repeated when the new hub/rotor is installed.
Make sure you reinstall the wheel lug nuts with proper torque values.
Rotor Turning and Torque.
Should I Turn My Rotors? Volvo does not support or advise re-machining of brake rotors, ever. If you look at
the machines most shops use to do this work they decide where to clamp the rotor down by eye-ball. When it
goes back on the car it is usually worse than when you started. And when you get new rotors - DO NOT let
anyone turn them before installation in order to "true them up". They are new, and in the best condition they
will ever be in. Don't let anyone screw them up before you ever use them. If your turned rotors are pulsating,
I suggest you throw them away and start over with a new set.