I takemy 99 v70 XC to the post office Sat morning about 2 miles from my house and I hear a big clunk and a horrible grinding sound in parking lot. I climb under car expecting to see the driveshaft hanging down. After 10 min of short backing up and pulling forward with just HORRIBLE metal grinding lurching clunking car... I can't find a thing wrong. People coming and going are looking at me like I'm nuts- then they hear the sounds the car is making and just shake their heads. I' m thinking the weekend is shot...tow truck...trip to the dealer...$1000 repair...etc. I calm down and start to think- I crawl next to rear pass. wheel while girlfriend drives slowly forward...loudest sound is from there! I decide to risk it and slowly limp back home to the tools.20 minutes later I am prying chucks of metalout of 1/2 inch space between inside rotor and heat shield... A 2 inch chunk of the inner base of the brake rotor had "popped out" and become wedged in this space. Is thisa faulty rotor? has anyone ever heard of this on any car?thepiece that broke out is notwhere the pads make contactor where the lugs go through- it is in between....I cleaned out the 6 or 7 pieces of metal...and put her back together and went on with my day.

 

Sounds like a porous casting, Any pics? Something must be comprimised. I'd replace the rotor, before another chunk decides to fly through someones windsheild.

 

New rotors on the way.... $50for a pair of the VolvoOEM's including shipping ....you gotta love eBay! I will post photos of the hole in the rotor and the bits as soon as Iswap them out.

 

Before you get to far ahead of your self remove the rotor and inspect the E-brake shoes.
There is a chance one of the linings came off and thats what broke the rotor.

 

Make sure that caliper is ok before you proceed. Piston may have popped due to a bad seal or a pitted piston. That happened to the fron on my v70. Replacing the rotor will take you all of 1/2 hour.

 

dunno where u are from but in canada where there are road salt.. the parking brake cable can be seized too can causing parking shoes to drag inside rotors.