Volvo introduced the S40 in 1995. The 2006 Volvo S40 was available in both two-wheel and all-wheel drive. Both versions of the 2006 S40 had four-wheel disc brakes available. The disc brake system incorporated the calipers, pads and rotors as the main brake parts for the car. The front disc brake calipers have a piston that compresses by simply pushing it inward. The rear brake calipers have rotating or splined pistons, which need to be rotated while compressing the piston to fit the new brake pads. Replacing all of the pads on all four wheels takes about three to four hours.
Instructions
1 Remove the torque from the wheel lug stems on one front wheel, using a 1/2-inch breaker bar and wheel socket set. Turn the lug stems until they are lightly broken loose from the wheel. The 2006 S40 has lug stems that turn into the wheel hub like bolts, rather than the usual wheel stem with a wheel nut that spins onto it. This inverted version of what most people are used to can be a bit tricky to work with. Lift the Volvo up, one side at a time, with a 2-ton jack or a jack with greater capacity. Place a jack stand underneath the lifted side of the vehicle, beneath the front frame rail. Take off one set of wheel lug stems, then repeat this step on the second front wheel of the car. Remove both front wheels completely from the car.
2 Remove the caliper mounting bolts on the rear of one of the brake calipers. The brake caliper is the large metal object wrapped around the metal disc or brake rotor. Remove the brake caliper halfway from the brake assembly, using a small pry bar to assist you. Do not pull the caliper completely off the brake assembly at this time. Insert the small pry bar into the hole on the caliper, placing the tip of the pry bar between the rear brake pad and the brake rotor. Push the handle of the pry bar away from the wheel well, in order to compress the brake caliper piston. Remove the brake caliper when the caliper piston is completely compressed or you can push it in no further.
3 Set the caliper onto the lower control arm, directly behind the brake rotor. Do not let the caliper hang freely, or you will damage the brittle rubber hose between the back of the caliper and the frame of the S40. Remove the old brake pads from the caliper mounting bracket, using a small pry bar to pull them loose if necessary. Install the new brake pads onto the caliper mounting bracket. Lubricate the back side of each brake pad (the metal shim side) using a tub of caliper grease. Proper lubrication is crucial to the performance of any automotive brake system.
4 Reinstall the brake caliper over the new pads and the brake rotor. Let the caliper sit on the brake assembly. Remove the two metal tubes from the rear of the caliper, which are set inside the little black rubber boots on the rear of the caliper. These tubes are known as the caliper slide tubes. Remove the tubes by pushing them out of one end of each rubber boot. Dip both slide tubes directly into the tub of caliper grease, then reinstall them into their rubber boot housing. Install the caliper mounting bolts back onto the caliper and tighten the mounting bolts between 60 and 70 foot-pounds of torque with a certified torque wrench and socket. Spray the entire brake assembly using a can of aerosol brake parts cleaner, to remove excess grease and greasy fingerprints.
5 Repeat Steps 2 through 4 on the other side of the S40 to complete the front pad replacement process. Lift the front side of the Volvo up using a 2-ton jack and remove the jack stand from beneath that side. Reinstall the front wheel and install the lug stems into the wheel hub. Tighten the front wheel to a snug position before dropping that side of the vehicle. Repeat this process on the other side of the Volvo to install the second front wheel. Make sure both sets of wheel lug stems are snug prior to dropping the car to the ground. Tighten the front wheel lug stems to 80 foot-pounds of torque using a certified torque wrench and wheel socket.
6 Remove the torque from the wheel lug stems on one rear wheel, using a 1/2-inch breaker bar and wheel socket set. Turn the lug stems until they are lightly broken loose from the wheel. Lift the Volvo up, one side at a time, with a 2-ton jack or a jack with greater capacity. Place a jack stand underneath the lifted side of the vehicle, beneath the rear axle beam. Take off one set of wheel lug stems, then repeat this step on the second rear wheel of the car. Remove both rear wheels completely from the car.
7 Remove the caliper mounting bolts on the rear of one of the rear brake calipers. The brake caliper is the large metal object wrapped around the metal disc or brake rotor. Remove the brake caliper completely from the brake assembly, using a small pry bar to assist you if necessary. Compress the rear caliper, using a 3/8-inch drive ratchet and 6-inch extension, with a caliper piston tool at the end of the extension. Push the caliper tool against the face of the piston and turn the caliper clockwise with the tool while simultaneously adding pressure to push the piston in. Repeat the compression procedure until the rear caliper piston is completely compressed.
8 Set the caliper onto the lower control arm, directly behind the brake rotor. Do not let the caliper hang freely or you will damage the brittle rubber hose between the back of the caliper and the frame of the S40. Remove the old brake pads from the caliper mounting bracket, using a small pry bar to pull them loose if necessary. Install the new brake pads onto the caliper mounting bracket. Lubricate the back side of each brake pad (the metal shim side) using a tub of caliper grease. Proper lubrication is crucial to the performance of any automotive brake system.
9 Reinstall the brake caliper over the new pads and the brake rotor. Let the caliper sit on the brake assembly. Remove the two metal tubes from the rear of the caliper, which are set inside the little black rubber boots on the rear of the caliper. These tubes are known as the caliper slide tubes. Remove the tubes by pushing them out of one end of each rubber boot. Dip both slide tubes directly into the tub of caliper grease, then reinstall them into their rubber boot housing. Install the caliper mounting bolts back onto the caliper and tighten the mounting bolts between 60 and 70 foot-pounds of torque with a certified torque wrench and socket. Spray the entire brake assembly using a can of aerosol brake parts cleaner, to remove excess grease and greasy fingerprints.
10 Repeat Steps 2 through 4 on the other side of the S40 to complete the front pad replacement process. Lift one rear side of the Volvo up using a 2-ton jack and remove the jack stand from beneath that side. Reinstall the rear wheel and install the lug stems into the wheel hub. Tighten the rear wheel to a snug position before dropping that side of the vehicle. Repeat this process on the second side of the Volvo to install the second rear wheel. Make sure both sets of wheel lug stems are snug prior to dropping the car to the ground. Tighten the rear wheel lug stems to 80 foot-pounds of torque using a certified torque wrench and wheel socket.
