The brakes on my '90 240 started making a thump-thump sound when braking. Found that the rear pads were worn. While replacing the pads, I found a stuck caliper - so it has to come off to be rebuilt. Problem is that I couldn't get the brake line off the old caliper. It's stuck in there real good. Since the nut is now rounded off, I need to replace the brake line. However, I can't seem to find any replacement hard brake lines for the rear. FCP seems to stock the fronts but I don't see any for the rear. Anyone out there have a source for this?

I found this site that seems to stock copper-nickel lines of various sizes:

http://www.jegs.com/p/JEGS-Performan...11534/10002/-1

My measurements show the lines to be 3/16" but I don't know what size the fittings are. Anyone use these before? If so, do you know the fitting sizes needed?

Try http://www.volvopartswebstore.com/ for rear brake pipes.


Brake pipe Left (1277112) Index #29 on diagram below. $19.44
Brake pipe Right (1277114) Index #30 on diagram below. $19.44

Before opening any line (s), used a prop to hold the brake pedal depressed about 1 1/2 inches. That will prevent fluid loss from Master Cylinder. Only a few drops will be lost from open line fittings.




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Bruce Young, '93 940-NA (current), 240s (one V8), 140s, 122s, since '63.

How did you manage to find the part on the volvopartswebstore? I had looked at their site but it doesn't even let me enter 240 as my volvo model. This is the simplest solution rather than try to source all of the parts to fabricate my own.

Placing the order now. Thanks for the help.

I sort of "back into" it knowing that a part number of something physically close will make the detailed drawing available. In this case I think I started with rear flex hose 1229100 in the first search window at http://www.volvopartswebstore.com/

Then clicked on "Fullsize Image" on the resulting Brake Lines screen.

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Bruce Young, '93 940-NA (current), 240s (one V8), 140s, 122s, since '63.

In a footnote to extinct 240 brake parts, Volvo has discontinued the "backing plates" on both the front and rear ends for both ABS and non-ABS 240 models. You can still, however, get both fronts and one of the rear backing plates via IPD etc. for non-ABS models.

The left and right fronts are interchangeable and that internal Volvo number is 1272469.

The rear, driver's side is still available from IPD etc., as well. That number is 1205785.

The rear, passenger side is absolutely extinct in the U.S. - including the U.S. dealer network. However, I was able to find an ample supply at both CVI Automotive and VP Autoparts. That part number is 1205786. The CVI website was also very easy to navigate and shipping costs/customs etc.. were clearly stated and calculated on the ordering page.

Link for 1272469:
http://www.ipdusa.com/products/9050/120354-front-brake-dust-shield-backing-plate-240-260

Link for 1205785:
http://www.ipdusa.com/products/9055/120357-rear-left-brake-dust-shield-backing-plate-240-260

Link for 1205786:
http://www.cvi-automotive.se/en/articles/15085/51e-rear-ate

The dust shield is mainly to protect the bearings in front and the parking brake mechanism at the rear. So you don't need to shield the rear braking surface of the rotors but just cover the rear indent in the rotors.

I cut circles out of plastic pail lids to serve the purpose.

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1980 245 Canadian B21A with SU carb, M46 trans, 3:31 dif, in Brampton, Ont.

You could likely source tubing for the lines at a NAPA or other similar auto parts source in town, but in my experience the hang up is in sourcing the correct fittings, which you mentioned, AND in replicating the flares at the end of the lines you have fabricated. Euro car makers use metric DIN/ISO flares, or bubble flares, and it takes a special tool to make them.

Here is a link to a tutorial -

http://www.matthewsvolvosite.com/forums/viewtopic.php?f=1&t=32317

Here is a link to a source for tubing and fittings -

http://store.fedhillusa.com/316directory.aspx

Here is a link for the DIN flare tool -

http://shop.advanceautoparts.com/p/otc-bubble-i.s.o.-flaring-tool-kit-otc4504/17631617-P

Thanks for the link. I managed to get the line off. The rear seems to have a male nut that goes into the caliper while the end that goes to the flex hose seems to have a female connector. I looked at the FedHill site and it looks to me that this might be the correct nut for flex hose end:

http://store.fedhillusa.com/m33.aspx

It says it has an SAE flare (45 degree/inverted bubble). Do you know if this is the correct flare?

For the caliper end, there are several that may be correct but I can't be sure and after reading matthewsvolvosite, it looks like I need to be careful. These are the ones I found on FedHill

http://store.fedhillusa.com/m13.aspx
http://store.fedhillusa.com/m1l3.aspx

I think that the m13 is the correct one - can anyone confirm?

Volvo dealers still stock these lines. Try Tasca or Borton Volvo. Last time I bought one, they were not that expensive.
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See the 700/900 "FAQ" at the menu bar top screen left side.