Did the classic Volvo OE rotor and pad swap on all 4 corners at 70K miles (past weekend). After bleeding all of the dark matter out of the hydraulics with fresh clean fluid, the pedal was incredibly soft.
I assumed I had managed to get some air in the hydraulics so another 2 quarts of fresh fluid, but not a single bubble came out. Yep pedal was still mush. I reinspected everything and found the cause, the spring clip on the left front caliper got installed (by me) with the ends of it above the blocks, not below. See http://volvospeed.com/850fbrake1.php for proper installation.
Apparently the spring when installed wrong causes the outer pad/ outer half of the caliper to stay away from the rotor, so when you push the pedal, it has to move some distance until the pad meets the rotor.
Thought I'd pass it on to possibly save someones time and a few quarts of brake fluid!
jorrell
2006 XC70, 2012 C30 new to me
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