Introduction

This guide will show you how to remove and replace the front brake rotors on the '86-'93 Volvo 240.

Whenever working on brakes, it is a good idea to keep one side assembled to use as a reference. Never drive a car that has only had its brakes on one side changed, as this will cause the car to pull to one side when braking.

Jack up the front of the car and place it on jack stands. Never work on or underneath a car that is only supported by a jack. The jack may slip or fail, resulting in serious injury or even death. Use an impact wrench or lug wrench to remove the five 19 mm lug nuts from the front wheel.
  • Jack up the front of the car and place it on jack stands.

    • Never work on or underneath a car that is only supported by a jack. The jack may slip or fail, resulting in serious injury or even death.

  • Use an impact wrench or lug wrench to remove the five 19 mm lug nuts from the front wheel.

    • The wheel lug nuts should be torqued to 85 ft-lbs when the wheels are put back on the car.

  • Pull the front wheel off the wheel lugs and set it aside.

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Use a 15 mm box end wrench to remove the two bolts on the back of the brake caliper. Use a 15 mm box end wrench to remove the two bolts on the back of the brake caliper.
  • Use a 15 mm box end wrench to remove the two bolts on the back of the brake caliper.

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Lift the brake caliper off the rotor and set it aside. Place the caliper on some type of support so that you do not put too much strain on the brake hose.
  • Lift the brake caliper off the rotor and set it aside.

  • Place the caliper on some type of support so that you do not put too much strain on the brake hose.

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Pull the brake rotor straight off the wheel lugs to remove it.
  • Pull the brake rotor straight off the wheel lugs to remove it.

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Place the new brake rotor over the wheel lugs.
  • Place the new brake rotor over the wheel lugs.

  • Most new brake rotors can be installed without any additional work, but if your rotors are out of round they will need to be turned.

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Conclusion

To reassemble your device, follow these instructions in reverse order starting at Step 3.

Brett Hartt

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