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Leaking brake lines S40-V40

Brake lines rusted through and leaking on my 2001 S40.They rusted in the rear above the gas filter where they elbow around.How much of a job is it to replace them?Any one had this problem?Any info is appreciated.








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    Leaking brake lines S40-V40

    Most unusual. First, I would get on the NHTSA web site and post the problem as this is a critical safety issue. You do not even live in a road salt state. Then write Volvo explaining the problem, don't call as that is not recorded and doesn't leave a record with you.

    Check the hard line. It has a connection to the flexible line and there should be another connector forward where the bent line attaches to the straight line going under the car that goes to the front. Finding a hard brake line is the hard part, or a shop can use the existing line to fabricate a new section. I do not suggest you try bending and flaring a brake line.

    While the line is off, I suggest replacing the flexible line at the same time. A good brake fluid flush for all lines is then needed.

    Sounds like your S40 got the same brake lines as Subaru, which is going through a recall.
    --
    My back feels better when I sit in a Volvo seat








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      Leaking brake lines S40-V40

      Flaring and bending brakes lines is just a little more difficult than working with soft copper (which must not be used for brake lines). It does require the correct dies to make the double or bubble flare, and a tubing bender. Matthews has a write up on flaring brake lines.

      If the part is still available through Volvo, that would be the way to go. Volvo Parts Webstore shows more brake lines than Tasca.

      Greg








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        Leaking brake lines S40-V40

        Thanks for the tip.I'll look & see if Volvo parts webstore has them








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          Leaking brake lines S40-V40

          I found brake lines.How much of a job is it to install them?I don't have access to a lift so I'd have to crawl under with jack stands.








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            Leaking brake lines S40-V40

            It depends. Do your solid brake lines go all the way to the caliper, or are there flex lines from the caliper to the hard line? If the hard line goes to the caliper, it may be difficult to get it off. You need to use a wrench to get the brass fitting off the caliper, NO pliers or any other tool that can deform the soft brass fitting.

            You also need a suitable container and 1/4 inch clear line to drain the brake fluid. Use the bleeder nipples for this. Any brake fluid that gets on the car needs to be wiped up because it will mess with the paint.

            Jack stands are OK. Just do one rear wheel at a time.

            My old cars are so rusty and I have yet not been able to remove the brass fitting from any of my calipers - so I shop this job out.
            --
            My back feels better when I sit in a Volvo seat








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              Leaking brake lines S40-V40

              One more question.Do the rear hard lines go all the way to the ABS unit in one piece,or is there a junction under the master cylinder where it can be taken apart and replaced without having to disconnect them at the ABS unit.
              Thanks for all your input.








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                Leaking brake lines S40-V40

                Most hard lines have a joint just before the rear wheel well. You just have to follow it forward...
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                My back feels better when I sit in a Volvo seat








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            Leaking brake lines S40-V40

            It is not difficult, just awkward and time consuming. Replacing brakes lines is not a lot of fun. Even less if you have to crawl under the car. Not being a fan of jack stands, solid wooden blocks make me feel a lot better when I could be getting squished.

            First thing to do is check to see if the bleeder screws break off. If they do you will need a caliper for each broken screw. If the bleeders don't still have the rubber caps you can try squirting a little penetrating fluid in each bleeder before you break them off. It won't hurt to spray a little on the brake line joints. Use flare nut wrenches on the flare nuts. If the bleeders open, there are only two joints for the replacement line.

            Greg








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