[pure_driver]

All OEM rear disc brakes are 280mm from D2 to more powerfull D4/T5.

 

[[email protected]]

Is it a 1.6 or 2.0 D2? The 1.6 usually has the 278mm discs.
You can tell the difference between the 320mm and 300/278mm brakes just by looking though the wheels.
The 320mm calipers look like this:

They are usually only fitted to the higher-powered variants.

The 278mm and 300mm brakes are slightly more difficult to tell apart as they use the same caliper but with different caliper carrier brackets. The 278mm caliper and carrier looks like this:

The caliper carrier has the size cast into it along with the Volvo part number.. If the wheel spokes are in the right position then if you stand in front of the driver's side front wheel and look at the front of the top part of the caliper carrier you will see the part number and '278' cast into it, like this:

The 300mm caliper carrier has more prominent 'horns' at the top and bottom:

Again, they also have the size cast into the front o the top, along with the part number:

As far as replacement goes, the brake systems are made for Volvo by ATE. You can get OEM ATE parts that will be a bit cheaper than Volvo's It's mostly direct from the Mk2.5 Ford Focus parts bin (the 320mm brakes are the same as the ones fitted to the Focus ST).

The 278mm/300mm versions at least are really easy to change yourself. You need a jack, a wire brush (to clean off any brake dust and rust), a pair of pliers (to remove and reinstall the retaining spring) 7mm hex/allen key or socket (to undo the slider bolts the caliper rides on), a 13mm spanner or socket (to remove the caliper cariier from the hub), a crosshead screwdriver (to remove the disc retaining screw), some copper grease (to lubricate the slider bolts, back of the pads and wheel mating usrface on reassembly) and some blue Loctite (to secure the caliper carrier bolts on reassembly, though this is optional).

The images for the 320mm calliper and brake disc are not loading on my end . I am assuming I must have the 320mm brakes as my front callipers look like this, and not like the 280 & 300 mm callipers show.

Interestingly this is on a 2016 T2 auto 1.6 R-design, so the lowest power variant with the largest brakes.

If I am wrong please correct me before I purchase the wrong brake discs for a second time facepalm

 

[VeeForty Deetoo]

The images for the 320mm calliper and brake disc are not loading on my end . I am assuming I must have the 320mm brakes as my front callipers look like this, and not like the 280 & 300 mm callipers show.
Interestingly this is on a 2016 T2 auto 1.6 R-design, so the lowest power variant with the largest brakes.

If I am wrong please correct me before I purchase the wrong brake discs for a second time facepalm

Well, mine look nothing like yours, and they're 278. I do remember reading the auto's often have larger brakes...

 

[[email protected]]

So I changed my brake disc and break rotors today.
It took 6 hours. Things that may not be obvious to people are:

• The caliper guide bolts/pins are under covers. Don't start trying to undo the giant torx bolts on your front caliper if you have the 320mm brakes, I will update you on the concequences of this when they arise.
• If you are buying brake disc from eurocarparts their system is definitely not perfect at sorting between a Volvo V40 and ford focus 320mm/300mm disc. I ended up with having to return a pair for missing the locking bolt.
• The disc locking bolt torque seems to be unknown, but I went for 70nm (I think this is on the tight side)
• For my front calipers 70nm for the 18mm bolts which hold the caliper to the hub seem about right, but make sure you have a good quality 18mm socket as the one I have is now kaput, and barely survive the last torque. Again these are the 320mm brakes
• 70nm for the 13mm bolt on the rear seems insane I broke an extension and a 13mm socket trying to set it to 70nm. I will double check Vida but it seems very high torque.
• Be prepared for brake fluid to pour out the reservoir when you are retracting your caliper pistons, if it has been topped up or flushed since your last pad change.
• The eBay special generic piston windback tool is a 10/10 purchase, I found the M bit it my kit fitted perfectly. The tool isn't entirely intuitive. The goal is to apply pressure to the piston spin the piston apply pressure again. If you are lucky you can get into quite the follow spinning the nut and handle at the same time, but regardless it's a slow process.
• Whatever is in the Volvo OEM brake pants is nasty stuff. One bottle of brake clean was just enough to do all 4 corners. If you want to paint them or clean them up really good you will want a lot more.

Fyi these are just my thoughts and I am not a professional.

 

[VeeForty Deetoo]

glad you completed it! Some say to loosen the caliper bleed nipple and connect a hose to direct into an old tin before pushing back, saves the fluid expelling from the reservoir, and on other makes (vauxhall eg) you save flipping the cylinder seal