Brake Booster replacement
 

Brake Booster replacement:

First start by Disconnecting the Battery.

Then open the hood and remove the Upper torque mount cross member.

Next remove the Air filter housing.

The remove the Big Cover over the Relay/fuse panel under the hood.
Once the cover is off remove the 13mm nut for the Positive cable.

Then remove the 2 screws securing the Relay box into place.(one of the screws is under where the positive cable just came off)
Unplug the one harness from the box and move the box to the side.

Then reach under and unplug the ABS module. There is 2 plugs. One you have to push a little tab and fold the cover back to release the plug. The other is 2 push tabs then pull.

Ok here is where it will get a little tricky. Look where the ABS pump motor assembly bolts to the body. There is 3 10mm bolts remove them and make sure the pump motor is loose.(No need to disconnect the lines)
Remove the 2 screws holding the Master Cylinder to the booster.
Unplug the sensor in the booster. Remove the Line and Valve from inside the booster.

That should be about it from outside till the booster is loose.

Inside the car:

Remove the Lower dash panel on the drivers side.
Then remove the clip holding the brake pedal to the booster. Either slide the Pin out or slide the Arm off.(Forget which it has). Then remove the 4 13mm screws holding the Booster to the Firewall.

Now go back outside:

Then slide the Master cylinder off of the Booster and kind of pull and move to the side.
Might require Carefully bending some of the lines. Then slide the Booster out.(Most of the times it takes some work to get it slid out. It might take some time to slide it out just take your time.

Then install in reverse order.

It will take a little time to do. About 1/2 a day at home with Hand tools.

RE: Brake Booster replacement
 

would you reccommend purchasing a new brake booster , or can I get one from the junkyard from a wrecked s80. Also wondering could I get one from another model volvo, are they interchangeable? Thank you

RE: Brake Booster replacement
 

I would buy new because if you buy used it might be the same way.
Im not 100% sure but the S60 and V70 might be the same.

RE: Brake Booster replacement
 

depends if it has stc, dstc, or just abs

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RE: Brake Booster replacement
 

Most places will charge book time no matter how long it takes to replace it.

RE: Brake Booster replacement
 

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RE: Brake Booster replacement
 

i have a two week 2001 S80 2.9 with stc and my brakes hiss so i have come to the conclusion that it is brake booster since it seems to be a common problem so here is my question where i can find a new one for cheap volvo and fisher tires told me that its 700 for the booster and fishers said 620 so where did you find yours and hopefully for cheap. The labor was 260 is that okay for that type of service? THanks for the help in advance.

RE: Brake Booster replacement
 

We just bought a 1999 Volvo S80 T-6. We noticed on the test drive that when the brake pedal was released after a stop there was a slight hiss or whine from the brake pedal/booster or something else under the dash. It only happens on release of the pedal. There is no loss of brake power what so ever...Idea's, is this a brake boost issue? The car came with the DSTC option.

RE: Brake Booster replacement
 

Sounds like yes the booster is leaking.

sounds like mine is leaking as well... I just assumed that was how the system was designed..
for the first 1/3 of the pedal I dont really get much brake response but after that it seems to work fine...

how much should a new brake booster cost?

thanks

They are pretty expensive.

With DSTC it is around 500-600. W/o DSTC is around 200-300
I just special ordered one from california with DSTC for 220 through a car parts company I use often, so it is possible to get it without destroying your wallet

incase i dont get any responses on my recent thread this seems to be the right place to ask this...
anyways is the booster supposed to hold vacuum when the car is off???

or why is my vacuum pump working when the cars off???

Is the electronic valve broke inline between the pump and booster?

how do i find out?? its not broken like visually or anything... if thats what your asking. electronically maybe??? any tests i can run or would i get fault code?

Welp here's my story. 2003 S80 T6

Day 1. Car is perfect. Super happy, nothing wrong.

Day ~200: Really quiet hiss on release of brake pedal. Also note: electric sound after I turn the car off. Coming from just behind the engine on the driver's side. No change in braking ability.

Day ~220: Take the car in. Idiot can't find anything wrong, even though I show him the sound. $300 down the drain. Still brakes fine.

Day ~230: Damn loud hiss every second I'm in the car. Brakes fine, still.

Day ~260: Noticable change in braking ability. It's about half-way between Normal and "I forgot to turn the engine on, car is reversing backwards, and brakes are freaking hard to push."

Next week: Shop. Already confirmed brake booster with the people at the shop. Will drop around $650 total.

I'm having the same issue, when I release my brake I hear the hissing sound. I looked up brake booster on Amazon and came across this link: Amazon.com: A1 Cardone 533102 Remanufactured Power Brake Booster: Automotive

Can anyone vouch for this, or just tell me if I have the right part? Thanks.

You have to make sure it matches what your car has. STC DSTC etc.

How would I know what my car has exactly? Thanks.

2000 S80 Booster Replacement
 

I just replaced the Brake Booster on my 2000 S80 2.9L. It was easy for me and took 2 hours. The reason I needed to replace it was there was an intermittent hissing sound (Vacuum Leak) heard inside the cabin usually after releasing the brakes. It would stop if I just quickly tapped on the brake pedal. There was the "Service Engine" light and also an "Emissions Service Required" message on the display.

Not just that but the biggest problem I had was the Surging & erratic Idle. Got so bad that the lights would dim and the car was dying the day I replaced it.

After the change the car idles & runs perfect. No more messages and it passes inspection with flying colors.

Thank you all for the posts:)

Glad it all went well for you.

How do I figure out what technology my current brake booster has so that I know which kind of brake booster I should buy? Ex: STC,DSTC, etc

There should be a sticker on the booster showing STC or DSTC. I believe the DSTC has an extra solenoid on the booster. Mine, a Non DSTC had 1 switch and the vacuum line connection.

Also usually you have the switch inside the car under the A/C controls.

Put mine off as long as I could. I was hopeful based on some of these comments: https://volvoforums.com/forum/volvo-...ars-off-43983/ that i could wait - but alas, no. Began to see diminished power assist with brakes. Hiss was very loud and the dam booster buzz drove me crazy. $1,100 parts and labor with DSTC.

Source for Brake Booster
 

Advance Auto parts sells Cardone boosters for less than $200.00.

I used one on my 2000 S80 T6 with good results and am about to change the one on my 2003 S80 T6:)

Well, I am taking a chance on a used DSTC brake booster on my 1999 S80 with 181000 miles on it. Got the classic hiss. I JUST had to replace my ETM. Totally OEM, white sticker and all. Had it checked twice before the warrantee was up and both times it totally checked out. Tried to update the software and I said heck no. Mine went 172k miles before I had to by one from ZeModex. $549 and works like a charm. Should have never gone with the DSTC Volvo. Too expensive parts wise and rare.


UPDATE: Well, the used $480 booster was NOT a DSTC booster either. A new one from VOLVO was a non starter based on the value of the car. Well, I figured I would try pulling the seal out of a new cheap one (Non DSTC) I bought and putting it in my fully functional yet leaking original DSTC booster. Took a little time but it worked like a charm. Use a little RTV around the edge of the seal to prevent the dread seal popping back out. Of course that was the easier part, putting the thing back in.... well I think the Lord may be unhappy with my choice of words during that brutal process.

i imagine everyone here knows what brake boosters do? but thanks for your input.

I have a Volvo S 60.
Was making a "hissing" noise under the dash.
Everything worked otherwise.
I relaced the booster, put everything back together.
Bled the brakes starting with the right rear.
Now brakes tighten up when driving only a short distance.
I need help!

Tech - Thanks for your step by step on the brake booster replacement..it really helped..instead of figuring it out as I go( most of the time) I just replaced it on my 2001 V70, 2.4T..the biggest bitch was under the dash with those fine threaded nuts securing the booster to the firewall..UGH! I needed toremove the channel casing on the wire harness to the right of the booster, then it pretty much slid out. I hope this is good for another 100K!
Thanks again

Does anyone have a reasonably priced supplier for the brake booster for S80 T6 1999 STC
(part 9485180) that will supply to Australia?
Thanks Ken

Help
 

I have a 2001 S60, nonturbo with an automatic. I followed Tech's instructions to the letter with no issues during replacement. Upon starting the car I have several issues:
1. I cannot get the brake light switch to adjust.
2. ABS, Traction Control, and Brake lights are on.
3. Information display says "Brake System Failure".
4. Went for a test drive to check booster-seems fine-went around the block, upon returning at home, the speedometer zeroed out and felt as if in neutral. Revved to 3500 RPM to get in garage.

Please help-what could I have possibly screwed up? I am fairly mechanical and have never had an issue like this!

Well, you may not have screwed up anything. Try this first:


Disconnect battery for a few minutes and re-connect. Start car and see if the faults clear.


This is one of the ugly electrical issues with this vintage of Volvos. There are quite a few threads concerning this but none point to a specific issue. Sometimes it is the ABS module, others claim replacing the key cylinder lock worked, others say its a faulty ECU. In any case I have had the same issue for over a year.


The worst is when you are driving down the road and ALL of your warning lights come on and then your tach and speedometer drop to zero. Meanwhile, the car seems to operate just fine, you just don't have any gauges. Volvo spent 2 days trying to isolate the issue on my car and failed.

Re: Help
 

Just wanted to provide an update, had the car towed to my local independent Volvo shop; VIDA showed an ABS code. After tracing for about 5 minutes, they found that the large harness on the ABS controller had come partially unplugged. The brake light switch was also broken, and exacerbated by the booster replacement. Everything is good now.

Brake Booster With DSTC or without DSTC ??
 

I have a 2001 Volvo S80 T6 4-Door Sedan. It has STC option button, but not DSTC.

When I press the brake pedal, I get a hissing sound. And also the braking power has gone down considerably.

I am trying to buy a brake booster online. Some sites say I need to use Booster with DSTC while others say it's not required.

Please help me out here. Should I buy the booster With DSTC or without DSTC ??

Thanks

You don't need a DSTC brake booster which is a VERY expensive replacement part if you don't have the DSTC option. In fact, I am pretty sure it won't work in your car. Very few Volvos of that era had DSTC compared to STC. The cost difference between the two boosters is easily $450.


BTW, have you ever replaced a brake booster on an S80? It isn't complicated but expect to be upside down in the driver's seat for a very long time cursing the day you ever bought the car.

There sre some good instructions on this site for the procedure to replace the booster, but yes you will be upside down and cramped under the dash forever. If you have a small air ratchet (1/4") it could make a world of difference...anything larger wont maneuver under there..

2003 s80 t6 brake booster
 

followed step by step and did great, but is there more steps for a s80 T6? if so, what next? it seems there is turbo piping in the way or am I just not twisting and turning right. Doesn't look like it will come out :confused: