Question about 1996 Volvo 960

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92 960 wagon with ABS.

Wanting to know how difficult it is to replace the front brake rotors? Any instructions available out there?

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Very easy. Jack up the front of the car and support it with two sturdy jackstands. Remove the front wheels. To the brake fluid nipple on the caliper (the part that squeezed the pads against the rotor), attach a small tube leading to a drainpan, open the nipple, and push back the brake pads from the rotor with a broad screwdriver. Close the nipple. Be careful not to damage the pads if you are not replacing them. (It would be wise to replace the pads when you replace the rotors, though).

Two bolts hold the brake caliper onto the steering knuckle. Remove both bolts, preferably with an impact wrench, and remove the caliper. On some cars the bolts have indented 10mm hex-wrench heads rather than standard bolt heads, so you may need to acquire a new tool. Be careful to support the caliper so you do not damage the hydraulic brake hose. Slip the old rotor off the studs and replace it with your new one. New rotors are packed in oil which will damage your brake pads, so clean the new rotors with vinegar before installing them. Replace the caliper and pads. Check to see you have sufficient brake fluid in the master cylinder reservoir before operating the vehicle. If the brakes seem at all spongy, bring your car to a qualified mechanic to inspect your work and to bleed the brake hydraulic syatem. Always do both front rotors, never just one. Otherwise, your car will **** violently to one side when you brake.

Posted on Oct 10, 2008

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The ABS sensor is behind the rotor on the lower control arm pointed outward toward the rotor with a flat button face. You can not see the button face with the rotor installed. If the sensor is bad you will have an ABS light. I think your troubleshooting the wrong problem. i.e rotor vs your current focus of the ABS sensor.

I would like some feed back on the running dynamic on the road brake test.

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I think you should get the Tierod ends checked. When you get a Front-end alignment, the mechanic will check them. Although you turned the front Rotors, when you start Braking the front tires can wander differently than when they freewheel.

Sometimes you can get a rust problem on the Rotors that were just made shiny. Moisture on the pads imprints a rust blotch on the Rotor and they grab at the rust until the rust wears down. Then they are ok.

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Get your front-end checked first, then as the mechanic road tests it when the Alignment is complete, he can judge the brakes.,

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Your '93 Legacy was one of the first cars to provide ABS as standard. If your ABS is activating, you'll feel a fast pulsing feel when braking, is that what you experience? 
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