Fitting XC90 Calipers & 336mm Discs to S60 / V70

When I first bought my S60 it was wearing a set of standard 286mm discs which looked a bit worse for wear, first job was to replace these with 305mm discs using the original callipers but new carriers. The 305mm set up was fine BUT after a few years I wanted more…

I had read a few threads about fitting the callipers from an XC90 and running 336mm discs – this was the way forward.

First job was to get on eBay and order a set of callipers, found a decent looking set from a 2004 XC90 T6 for £100 delivered from Hills Salvage. These were delivered the next day:

http://i24.photobucket.com/albums/c2...0/DSC02750.jpg

http://i24.photobucket.com/albums/c2...0/DSC02760.jpg

http://i24.photobucket.com/albums/c2...0/DSC02765.jpg

The XC90 caliper are almost a direct fit to the S60 hub, the only modification is the XC90 Carriers use M14 bolts as opposed to the M12 on the standard S60. This meant that the Steering Limiter Arms would need drilling out to accommodate the new M14 bolts along with the Hub.

The S60 Hub is made from aluminium and would drill without issue, the Steering Limiter Arms are cast and much tougher to drill, I decided to buy a second set of limiter arms and have them drilled out by a local engineering firm in preparation:

http://i24.photobucket.com/albums/c2...0/DSC_0088.jpg

The M12 bolts from the original set up would be of no use, I needed to order some replacement M14 bolts but didn’t know the required length…..so I ordered a variety of M14 8.8 Zinc Plated bolts in 50mm 55mm 60mm lengths – I like to be prepared lol:

http://i24.photobucket.com/albums/c2...0/DSC02769.jpg

Decided to have the calipers professionally painted and whilst they were away for a few days, I ordered a caliper seal kit from Bigg Red:

http://i24.photobucket.com/albums/c2...0/DSC02773.jpg

Next on the shopping list was the 336mm discs and pads from Lloyds Volvo in Carlisle….discounted from £280 to £169.00 with next day delivery:

http://i24.photobucket.com/albums/c2...0/DSC02879.jpg

Just had to wait now for my calipers from the bodyshop…..

The calipers were blasted and painted in primer:

http://i24.photobucket.com/albums/c2...0/DSC_0090.jpg

A few days later, the calipers were back home and looking very Gold:

http://i24.photobucket.com/albums/c2...0/DSC02804.jpg

http://i24.photobucket.com/albums/c2...0/DSC02810.jpg

http://i24.photobucket.com/albums/c2...0/DSC02814.jpg

http://i24.photobucket.com/albums/c2...0/DSC02816.jpg

With the calipers looking very shiny and gold, I went ahead and fitted the caliper seal kit from Bigg Red so they’d be ready to be installed.

Tools out time…..

First job was to remove the old 305mm discs, pads and calipers along with the old limiter arms. Armed with a new 14mm drill bit and drill, I carefully drilled out the aluminium hubs in order for them to take the new 14mm bolts, this only took a couple of minutes and was surprisingly easy:

http://i24.photobucket.com/albums/c2...0/DSC02908.jpg

Did a trial fit of the XC90 carriers to determine the length of bolts needed, obviously too short and the carriers wouldn’t be secure, too long and the bolts would strike the disc…discovered 55mm bolts were perfect:

http://i24.photobucket.com/albums/c2...0/DSC02913.jpg

Confirming that 55mm bolts were now the ones to use, I removed the carrier to mount the new 336mm disc and then refitted the limiter arm and carrier:

http://i24.photobucket.com/albums/c2...0/DSC02914.jpg

http://i24.photobucket.com/albums/c2...0/DSC02931.jpg

Copper greased the new brake pads and fitted the inner pad with the rear section of the caliper after using silicon grease to lube the slider pins, fitted the flexi brake pipe and mounted the caliper:

http://i24.photobucket.com/albums/c2...0/DSC02916.jpg

Installed the outer pad and bolted up the rest of the caliper and carefully fitted the pad retaining clip, trying not to scratch the new paintjob lol:

http://i24.photobucket.com/albums/c2...0/DSC02928.jpg

http://i24.photobucket.com/albums/c2...0/DSC02923.jpg

Next was the straight forward job of bleeding the calipers, starting with the nearside and moving onto the offside, bled without any issues using ATE SuperBlue DOT4 fluid.

Carefully refitted the Comets and then stood back to admire my new 336mm setup:

http://i24.photobucket.com/albums/c2...0/DSC_0116.jpg

http://i24.photobucket.com/albums/c2...0/DSC02933.jpg

http://i24.photobucket.com/albums/c2...0/DSC02938.jpg

http://i24.photobucket.com/albums/c2...0/DSC_0115.jpg

A short test drive to make sure there were no issues, obviously brand new discs and pads will need bedding in for a few mile before I can really jump on the anchors.

A few folk have questioned if they’d be sufficient room behind 17” wheels, I was quite surprised how much room there was between the caliper and the Comet wheel. NOTE: 10mm Spacers are fitted:

http://i24.photobucket.com/albums/c2...0/DSC02934.jpg

http://i24.photobucket.com/albums/c2...0/DSC02937.jpg

I have also seen this setup using the 17” Tethys.

A quick comparison in sizes between the XC90 caliper and the original S60 caliper…..a massive difference:

http://i24.photobucket.com/albums/c2...0/DSC_0113.jpg

Also a comparison between the original 286mm discs, 305mm & 336mm discs:

http://i24.photobucket.com/albums/c2...XC90/DISCS.png

Happy Days :)

STUNNING mate! :)

Great write up mate

Nice job there,but where's the nebs gone ?.

Nebs are in the garage and will be swapped over next week lol. I just wanted to run the new brakes with the 17" Comets to make sure there weren't any issues or surprises.

One of the best upgrade to do, would you do the rears to?

thats a great write up and they look superb!

Great write up

Great write up,and good work mate.

Quote:

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Originally Posted by Rich v70

One of the best upgrade to do, would you do the rears to?

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Not sure exactly what's involved with the rears - caliper and discs wise

Looks good, nice write up.

Great thread this mate look brilliant too get the nebs back on :)

Looking excellent, very nice work and thread!

Excellent, super neat conversion.
Great work!

Great write up Steve & interested to know they fit behind comets. Maybe a good upgrade when I have more funds as I love a bit of braking power.
Wonder what the weight difference is with a view to unsprung weight?

Excellent write up and a great modification