03 Volvo S60 T5 Brake pedal vibration and crunch/rattle sound

Brake anti-rattle clips are used to reduce brake noise and vibration caused by loose-fitting brake pads. Here are the general steps for installing brake anti-rattle clips:

1. Remove the wheel/tire assembly from the vehicle.
2. Remove the brake pads from the caliper.
3. Clean the caliper, rotor, and brake pad mounting surfaces with brake cleaner and a wire brush.
4. Apply a thin layer of brake lubricant to the caliper, rotor, and brake pad mounting surfaces.
5. Install the brake pads into the caliper, making sure they are properly aligned and seated.
6. Install the brake anti-rattle clips onto the brake pad ears or shims. Some clips may have a specific orientation, so check the manufacturer's instructions.
7. Use a brake pad spreader tool or C-clamp to compress the caliper piston back into its bore. This will allow enough space for the brake pads to fit over the rotor with the anti-rattle clips in place.
8. Reinstall the caliper onto the rotor and torque the caliper bolts to the manufacturer's specifications.
9. Repeat the process for the other side of the vehicle.
10. Reinstall the wheel/tire assembly and torque the lug nuts to the manufacturer's specifications.
11. Pump the brake pedal a few times to ensure proper brake pad-to-rotor contact before driving the vehicle.

if it sounds like a clicking noise, it could be the rear sway bar links. or the rear exhaust bracket. both common problems with volvos

There should be an adjustment to take up the slack in the parking brake cable. Although, If the brakes were properly serviced, there should not be any looseness in the brake pads. There are sprays and stick on pads that go on the back of brake pads to prevent rattles and squeaking. It would necessitate removing the brake caliper and brake pads. Personally, I would take it back to the shop that did the job and make them fix it. New pads should not rattle.

How hard are you stepping on the brake pedal? What you are describing sounds like the ABS system activating. When you step on the pedal hard enough to engage the ABS the light will come on, in some cars it will blink. You will also feel the thumping/vibration in the pedal since the system works by repeatedly engaging and disengaging the brakes. If it is happening when you step lightly on the brakes then you may have a bad wheel speed sensor or possibly a bad or miss-adjusted brake switch.

the only thing i can think of as a problem would be brake pad quality. i would get some from the dealer and fit them. if there is chatter going on it can also be caused by low quality rotors or a bad maching job. have them inspected for integrity.

I had a similar problem. The dealer change automatic transmission and differential, but the noise continu. After research on internet i think the problem is the front galiper who create a vibration on the disc wheel and the vibration frequence follow the front axle until interior car. Just press slowly the brake pedal and if the noise stop , that's it the cause i think. I dont change my galiper, but i have a new transmission . :)))

the rear drum brakes work on foot and hand brake , noise under stain does it rattle could be a loose exhaust heat shield ,

sounds like u need front brake pads and rotors i would check brakes first if ok then i would check front wheel bearings but cv joints make a clicking sound usauly when turning

take it to autozone and they will plug in their OBD11 computer and tell you exactly what it means... or take it to any mechanic who has one, my light comes on if i get crappy cheap gas

Sounds as if a synchronizer is going out in 3rd gear, or 3rd gear maybe stripped. I would get it checked by a tranny (transmission) shop before it ended up costing you more money. There is a possibility that there may be some shavings on that gear as well, which would just need cleaned.