Volvo Volvo S40 1995-2004 Brakes Specifications
Explore detailed brake specifications for the 1995-2004 Volvo S40, including pad sizes, rotor dimensions, and maintenance tips. Ideal for owners, mechanics, and enthusiasts.
Overview Specifications
This document provides detailed specifications and technical information about the braking system of the 1995-2004 Volvo S40. It is designed to assist owners, mechanics, and enthusiasts in understanding the brake components, maintenance requirements, and performance characteristics. Use this guide to find information on brake types, dimensions, materials, and maintenance procedures. Whether you're performing routine maintenance or troubleshooting, this document will serve as a comprehensive resource.
How to Use
Use the search function to quickly locate specific brake components or terms. Enter keywords like 'brake pads', 'rotors', or 'calipers' to find relevant sections. The search results will highlight where the information appears in the document.
Navigate through the document using the section titles and subsections. Each major section covers a specific aspect of the braking system. Click on a subsection to expand it and view detailed information. Use the quick reference section for fast access to key specifications.
Key Specifications
Front Brake Disc Diameter
280 mm
Rear Brake Disc Diameter
280 mm
Brake Pad Thickness (New)
10-12 mm
Minimum Rotor Thickness (Front)
22 mm
Minimum Rotor Thickness (Rear)
10 mm
Available Specifications
Brake System Overview
This section provides an overview of the braking system components, including the types of brakes used, their configuration, and general performance characteristics. Learn about the front and rear brake systems, their differences, and how they work together to ensure safe stopping.
Brake System Overview
This section provides an overview of the braking system components, including the types of brakes used, their configuration, and general performance characteristics. Learn about the front and rear brake systems, their differences, and how they work together to ensure safe stopping.
Front Brakes
- Ventilated disc brakes for improved heat dissipation
- Single-piston floating calipers
- Disc diameter: 280 mm (11.02 inches)
- Pad material: Semi-metallic or ceramic options
Rear Brakes
- Solid disc brakes for consistent performance
- Single-piston floating calipers
- Disc diameter: 280 mm (11.02 inches)
- Pad material: Semi-metallic or organic options
Brake Components
This section details the individual components of the braking system, including brake pads, rotors, calipers, and hydraulic systems. Understand the materials, dimensions, and functions of each part to better maintain and replace them as needed.
Brake Components
This section details the individual components of the braking system, including brake pads, rotors, calipers, and hydraulic systems. Understand the materials, dimensions, and functions of each part to better maintain and replace them as needed.
Brake Pads
- Available in semi-metallic, ceramic, and organic materials
- Thickness: 10-12 mm when new
- Wear indicator included for safety
- Replacement interval: 30,000-70,000 miles depending on usage
Brake Rotors
- Front rotors: Ventilated design, 280 mm diameter
- Rear rotors: Solid design, 280 mm diameter
- Minimum thickness: 22 mm for front, 10 mm for rear
- Made from cast iron for durability
Maintenance and Care
This section covers essential maintenance practices to keep the braking system in optimal condition. Learn about inspection intervals, common issues, and how to address them. Proper care extends the life of your brakes and ensures safety.
Maintenance and Care
This section covers essential maintenance practices to keep the braking system in optimal condition. Learn about inspection intervals, common issues, and how to address them. Proper care extends the life of your brakes and ensures safety.
Inspection Guidelines
- Check brake pad thickness every 10,000 miles
- Inspect rotors for wear and warping during pad replacement
- Monitor brake fluid level and condition every 15,000 miles
- Look for signs of leaks in the hydraulic system
Common Issues
- Squeaking or grinding noises indicate worn pads or rotors
- Brake fluid leaks may require caliper or hose replacement
- Pulsation in the brake pedal suggests warped rotors
- Reduced braking efficiency may indicate air in the hydraulic system
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Brakes Specifications
Overview
- Type
- Hydraulic disc brakes
- Configuration
- Front and rear disc brakes
- Platform
- Volvo P1 platform
- Material
- Cast iron rotors with ceramic pads
- Location
- Front and rear axles
Dimensions
- Front Rotor Diameter
- 11.8 inches (300 mm)
- Rear Rotor Diameter
- 10.2 inches (260 mm)
- Front Rotor Thickness
- 0.98 inches (25 mm)
- Rear Rotor Thickness
- 0.79 inches (20 mm)
- Brake Pad Thickness
- 0.47 inches (12 mm)
- Brake Caliper Piston Diameter
- 1.97 inches (50 mm)
- Brake Line Diameter
- 0.31 inches (8 mm)
Materials
- Rotors
- Cast iron with anti-corrosion coating
- Brake Pads
- Ceramic composite
- Brake Lines
- Reinforced rubber with steel braiding
- Calipers
- Aluminum alloy
Features
- Performance
-
- High thermal capacity rotors
- Low dust ceramic pads
- Progressive brake pedal feel
- Durability
-
- Corrosion-resistant rotors
- Long-lasting ceramic pads
- Reinforced brake lines
- Safety
-
- ABS integration
- Electronic brake force distribution
- Emergency brake assist
- Maintenance
-
- Wear sensors on brake pads
- Easy-access caliper design
- Self-adjusting parking brake
- Comfort
-
- Quiet operation
- Smooth braking response
- Minimal pedal vibration
Safety Features
- Active Safety
-
- Anti-lock Braking System (ABS)
- Electronic Brake-force Distribution (EBD)
- Passive Safety
-
- Reinforced brake lines
- Dual-circuit hydraulic system
- Emergency Features
-
- Emergency brake assist
- Automatic brake drying
Comfort Features
- Noise Reduction
-
- Ceramic brake pads
- Vibration dampening rotors
- Pedal Feel
-
- Linear brake response
- Adjustable pedal height
- Maintenance Ease
-
- Wear indicator alerts
- Tool-free pad replacement
Accessories
- Upgrades
-
- Performance rotors
- High-performance brake pads
- Stainless steel brake lines
- Maintenance Tools
-
- Brake pad spreader
- Caliper piston tool
- Brake fluid tester
- Cleaning Supplies
-
- Brake cleaner spray
- Rotor cleaning brush
- Caliper grease
Maintenance
- Service interval
- Every 30,000 miles or 24 months
- Service Items
-
- Inspect brake pads and rotors
- Check brake fluid level
- Test brake system pressure
- Lubricate caliper pins
- Inspect brake lines for leaks
- Maintenance Notes
- Use only DOT 4 brake fluid. Replace brake fluid every 2 years.
Warranty
- Brake Pads
- Miles: 30,000Years: 2Coverage: Material defects
- Rotors
- Miles: 50,000Years: 3Coverage: Warping and cracking
- Calipers
- Miles: 60,000Years: 5Coverage: Seal failure and piston issues
- Brake Lines
- Miles: LifetimeYears: LifetimeCoverage: Corrosion and leaks
Production Details
- Manufacturer
- Volvo Cars
- Manufacturing Process
-
- Precision casting of rotors
- CNC machining of calipers
- Automated assembly of brake pads
- Quality Control
- Rotor inspection: Ultrasonic testing for defectsPad Testing: Friction coefficient verificationCaliper Testing: Hydraulic pressure testing
- Sustainability Practices
-
- Recycled materials in brake pads
- Eco-friendly brake fluid
- Low-emission manufacturing
- Production Metrics
- Annual Output: 500,000 brake systemsDefect Rate: 0.01%Energy Efficiency: 95%
Service Information for brakes Service
Maintenance and service requirements specific to this component
- Inspect brake pads and rotors
- Check brake fluid level
- Test brake system pressure
- Lubricate caliper pins
- Inspect brake lines for leaks
Use only DOT 4 brake fluid. Replace brake fluid every 2 years.
- Replace brake pads
- Resurface or replace rotors
- Flush brake fluid
- Inspect caliper seals
- Check parking brake adjustment
Special tools required for caliper service.
- Replace brake rotors
- Inspect and replace calipers if needed
- Replace brake lines
- Test ABS system
- Perform full brake system bleed
Critical to use OEM parts for ABS system compatibility.
Frequently Asked Questions
Find answers to common questions about torque specifications
Q1 Are these brakes compatible with all 1995-2004 Volvo S40 models?
Are these brakes compatible with all 1995-2004 Volvo S40 models?
The brakes are designed to be compatible with all 1995-2004 Volvo S40 models, including both the 1.9L and 2.0L engine variants. However, it is recommended to verify the specific brake rotor and pad sizes, as some trims may have slight variations. Always cross-check the part numbers with your vehicle's VIN or consult a Volvo dealer for confirmation.
Q2 What is the recommended maintenance schedule for Volvo S40 brakes?
What is the recommended maintenance schedule for Volvo S40 brakes?
Volvo recommends inspecting the brake system every 10,000 miles or annually, whichever comes first. Brake pads should be replaced when they reach a thickness of 3mm or less, and rotors should be checked for wear, warping, or scoring. Additionally, brake fluid should be flushed and replaced every 2 years or 30,000 miles to ensure optimal performance.
Q3 How do I replace the brake pads on a 1995-2004 Volvo S40?
How do I replace the brake pads on a 1995-2004 Volvo S40?
To replace the brake pads, first, lift the vehicle and remove the wheels. Use a wrench to remove the caliper bolts and carefully detach the caliper. Remove the old brake pads and compress the caliper piston using a C-clamp. Install the new pads, reattach the caliper, and secure the bolts. Finally, reinstall the wheels and lower the vehicle. Always test the brakes before driving.
Q4 What should I do if my brakes are squeaking or vibrating?
What should I do if my brakes are squeaking or vibrating?
Squeaking or vibrating brakes may indicate worn pads, uneven rotor surfaces, or debris in the braking system. Inspect the pads and rotors for wear or damage. If the rotors are warped, they may need resurfacing or replacement. Clean the brake components thoroughly and apply brake grease to the back of the pads to reduce noise. If issues persist, consult a professional.
Q5 How can I optimize the performance of my Volvo S40 brakes?
How can I optimize the performance of my Volvo S40 brakes?
To optimize brake performance, use high-quality brake pads and rotors designed for your Volvo S40. Ensure proper bedding-in of new pads by following the manufacturer's instructions. Regularly check and maintain brake fluid levels, and avoid aggressive driving habits that cause excessive wear. Upgrading to performance brake components can also enhance stopping power and heat dissipation.
Factory Service Resources
Access official service manuals, technical documents, and repair guides. These resources provide detailed procedures, specifications, and diagrams directly from the manufacturer.
Volvo S40 Service Manual (1995-2004)
Coming SoonComprehensive guide covering brake system maintenance, repair, and troubleshooting for 1995-2004 Volvo S40 models.
Volvo Technical Service Bulletin: Brake System Updates
Coming SoonDetails updates and improvements to the brake system for 1995-2004 Volvo S40 models, including part revisions and installation instructions.
Volvo S40 Brake Parts Catalog
Coming SoonCatalog listing all brake components, including pads, rotors, and calipers, for 1995-2004 Volvo S40 models.
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Technical Information
- All specifications, including torque values, fluid capacities, and maintenance procedures, should be verified against your vehicle's factory service manual.
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