I have a 2008 Volvo XC90, 3.2L, 6 Cyl, AWD

I changed the front rotors and brake pads. I did not bleed from any of the bleeder nipples on the front. I just pushed back the pistons in w a clamp.

After 15 minutes of driving, I noticed that my calipers were sticking. My rims were hot to the touch. The rotors were so hot you cant even touch. I can smell burnt pads. My tires pressure went down as indicated my my TPS.

I bled the whole system. RR, RL, FR and FL. Cleaned all guide and locating pins, regreased, changed both brake hoses. No luck. Calipers are still sticking after 15 mins of driving.

I rebuilt the calipers. Changed the square seals and boots. Bled all wheels. No longer sticking

However, the brake pedal is now spongy. I tried to bleed all wheels but not much pressure is coming out. Even constant pressing of the pedal and bleeder valve is open. Fluid is not flowing.

The brake pedal is spongy, I hear hissing sound by the brake pedal.

I inspected the brake lines and brake hoses connections and bleeder valves on all wheels and any of the connections by the master cylinder or control module - no leak. Is this a Master Cylinder issue or brake power booster?

 

Parts Replace:
Front Brake Rotors from Brake disc for 2008 Volvo XC90. #30657301

Front Brake Pads from Brake pad kit for 2008 Volvo. #30793943

Front Brake Hoses from NAPA AUTO PARTS

Front Caliper Rebuild Kit from 08 2008 Volvo XC90 Caliper Repair Kit - Brake - Centric, Front, Rear - PartsGeek

Video How to Rebuild Brake Caliper
Video How to change brake rotors and pads

 

Btw...If you have a a bad Volvo XC90 Brake Caliper, you can rebuild for $7 as oppose to spending over $300 for a new one. Theres a lot of videos out there how to do it. Rebuilding a Volvo Caliper is very simple. Watch the video above. WARNING: Never put your hand infront of the piston when blowing it out of the bore. Connect the whole caliper, bolt it together, place a wood block so the piston dont overshoot when you are trying to blow it out. In addition, the Volvo XC90 caliper boot can be seated in the groove before inserting the piston into the bore. The boot has a wire embedded in the outer rim. After seating the pston into the bore, you just have to push in the outer lip of the boot to seat.