Replacing the Front Brake Discs on a Volvo 240 – Step by Step

Signs it's time

A 240 that shakes in the steering wheel or pedal under braking, squeals with a metallic sound, or pulls to one side usually points to the front discs. Other clear signs include visible scoring on the braking surface, a lip forming at the outer edge of the disc, or pads that are unevenly worn between the left and right side. Vibrations are usually caused by the disc having become warped (running out of true) rather than being too thin, but both faults are fixed the same way – replacement.

Two systems to keep apart

The Volvo 240 was fitted with several brake configurations depending on model year and engine. Earlier cars with the B20/B21 engine usually have solid (non-ventilated) discs on an ATE caliper, while later cars with a Girling caliper and ABS have ventilated discs with cooling channels between the braking surfaces. Check the edge of the disc – ventilated discs are thicker and have visible holes or channels between the two braking surfaces. Check which system your car has before ordering, otherwise neither the disc nor the fitting kit will fit.

What you'll need

• New brake disc for the correct side and system
• New brake pads, ideally replaced together with the discs so wear stays even
• Fitting kit with springs, washers and guide sleeves for the pads
• Brake fluid to top up after the caliper has been lifted away
• Torque wrench, piston retractor or a large G-clamp, plus standard hand tools

If the caliper has been sticking, leaking, or feels sluggish when the piston is pushed back, it's wise to inspect it at the same time – otherwise new pads will soon be bearing against a faulty piston and wearing incorrectly again.

How to do it

1. Lift the car and remove the wheel. Leave the handbrake off during the work.
2. Unbolt the caliper from the bracket (not the brake hose) and hang it securely from the suspension so the hose isn't under strain.
3. Remove the guide pins and lift off the old caliper, noting how the springs and washers are fitted.
4. Pull the old disc off the hub. If it's stuck, tap gently around it with a rubber mallet.
5. Clean any rust off the hub flange before fitting the new disc – debris between the disc and hub will cause runout even with a perfectly new disc.
6. Fit the new pads using the fitting kit's springs and washers in the correct orientation.
7. Carefully push the caliper piston back using a piston retractor or clamp, refit the caliper, and tighten the guide pins to the correct torque.
8. Pump the brake pedal a few times before test driving so the pads seat against the disc, and check the brake fluid level.

Products for the job

For cars with solid discs and an ATE caliper, the Bromsskiva ATE fram fits together with Bromsbelägg ATE fram and Monteringssats bromsbelägg fram, ATE.

If your 240 has ventilated discs with a Girling caliper, the Bromsskiva ventilerad fits together with Monteringssats bromsbelägg till Volvo 240, ventilerade.

If the caliper is sticking or leaking at the seals, there's a Reparationssats bromsok fram, Girling available for a rebuild instead of a whole new caliper.

Always replace discs and pads in pairs on the same axle, so the car brakes straight and evenly on both sides.