Brake Cables - Replacement: Removal & Installation Volvo S60 I

Remove the center console

See Parking brake lever, replacing.

Release the parking brake adjuster

See Release the handbrake adjuster.

Scheme 190

Take hold of the mechanical cable and bend it to the side so that it can be removed.

Scheme 191

Note. Raise the car.

Bend a thick metal wire (welding rod) as shown in the illustration.

Secure the wire in the cable eyelet. Bend the wire over the eyelet.

Scheme 192

1. Slacken off both the screws for the heat deflector plate
2. work the heat deflector plate down
3. remove the rubber grommet for the parking brake.

Scheme 193

Remove the mounting screws for the brake caliper. Hang the caliper from the spring. Use a wire so as not to damage the brake pipe.

Remove the locating pin and the brake disc.

Note. Do not damage the ABS line.

Scheme 194

Remove

1. the return spring at the expander
2. the expander. Lift the brake shoe slightly. Grip the expander and pull it outwards to access the cable.

Unhook or pry apart the expander (1) by the mechanical cable to remove it.

Scheme 195

Insert a screwdriver between the guide sleeve lug and the wheel unit. Pry apart slightly to remove the sleeve.

Scheme 196

Remove the clamp (1) by the tie rod.

Remove the mechanical cable from its mountings (2).

Pull the mechanical cable from the floor until the welding rod is visible (3).

Remove the mechanical cable from the welding rod.

Note. Leave the welding rod in the hole in the floor.

Scheme 197

Lubricate the O-ring on the wheel unit lightly using petroleum jelly.

Install and press the guide lug for the cable sleeve into place in the wheel unit.

Note. This is important for the operation of the parking brake.

Scheme 198

Install

1. the expander on the cable. Press the mounting together to lock the cable in the expander
2. the expander between the brake shoes
3. the return spring.

Check the function.

Scheme 199

Secure the cable in its clamps and on the welding rod.

Bend the welding rod over the end of the cable.

Install the cable in the hole in the floor.

Press the rubber grommet into the hole in the floor.

Press the mechanical cable into place in its mounting between the heat shield and the fuel tank.

Press the cable between the fuel tank and the edge of the heat deflector (the anti-vibration shield should be inside the edge).

Lower the car

See also:
• Installing wheels