1986-1993 Volvo 240 Brake Master Cylinder Replacement

If your Volvo 240's brake pedal is especially...

iFixit Library 1986-1993 Volvo 240 Moderate 30 - 45 minutes Guide 8631

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Guide overview

Before you begin

If your Volvo 240's brake pedal is especially soft or loses pressure while you're holding the brakes, it could be a bad seal in the master cylinder.

Step 1

Repair step

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PART USED ON THIS STEP Brake Master Cylinder Referenced by the iFixit guide

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The brake master cylinder is located directly underneath the brake fluid reservoir near the driver side of the engine bay.

Step 2

Repair step

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PART USED ON THIS STEP Clean Rag Referenced by the iFixit guide

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Twist the brake fluid reservoir cap counterclockwise and remove it.
Remove as much brake fluid from the reservoir as possible by sticking a clean rag inside the reservoir.
When you remove the rag, be sure not to place it on any painted or plastic surfaces. Brake fluid will strip paint and deteriorate plastic.

Step 3

Repair step

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If your brake fluid reservoir has a fluid level sensor, disconnect it by pressing down on the plastic tab and pulling the connector straight out of its socket.

Step 4

Repair step

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PART USED ON THIS STEP Brake Master Cylinder Referenced by the iFixit guide

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PART USED ON THIS STEP Clean Rag Referenced by the iFixit guide

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Use a 10 mm open end wrench to disconnect the two brake lines from the master cylinder.
There were still be fluid in the master cylinder that will drip out of the connections; this is normal. Use a clean rag to clean up any dripping fluid.

Step 5

Repair step

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TOOL USED ON THIS STEP 17 mm Socket Wrench Referenced by the iFixit guide

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PART USED ON THIS STEP Brake Master Cylinder Referenced by the iFixit guide

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Use an open end or socket wrench to remove the 17 mm nuts on either side of the master cylinder that attach it to the brake booster.
Remove the brake master cylinder, taking care not to damage or bend the brake lines.