IMPACT 4.04.

00 15/11/2024

Chassis ID Path
A 829664 5120/Repair//Rear wheel brakes, overhaul. Brake drum removed

Model Identity
FM (4) 149418768

Publish date ID/Operation

51205-3 Rear wheel brakes, overhaul

Illustrations may differ slightly from the actual vehicle being serviced. However, key
components addressed in this information are represented as accurately as possible.

All threaded fasteners that do not have a tightening torque specification in the information are
tightened to a standard torque. Standard torques are available in the following specification.➠
Standard tightening torques

Special tools

9994034 9998225 9998226

1 Remove the nuts.

2 Remove the brake anchorage.

Note
Note the positions.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

3 Remove the clip.

4 Remove the protection.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

5 Remove the screw and nut.

6 Remove the brake lever.

Note
Mark the position.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

7 Remove the gasket.

8 Remove the screws.

9 Remove the bracket.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

10 Remove the screws.

11 Remove the anchorage.

Note
Mark the position.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

12 Remove the protection.

13 Remove the screws.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

14 Remove the bracket.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

15 Remove the seal and bushing.

Note
Note the direction of assembly.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

A HANDLE 9992613

B MANDREL 9996298

16 Install the bushing.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

A HANDLE 9992613

B MANDREL 9998135

17 Install the seal.

Note
Respect the direction of assembly.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

A HANDLE 9992613

B MANDREL 9998135

18 Remove the bellows.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

19 Remove the adjusting lever.

Required material

EXTRACTOR 9998226

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

20 Remove the spring.

21 Remove the locking device.

22 Remove the pinion.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

23 Remove the screws.

24 Remove the cover.

25 Remove the gasket.

26 Remove the toothed pin.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

27 Disengage the dust cover.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

28 Remove the pressure screw assemblies.

Note
Note the positions.

29 Remove the pressure pivots.

Note
Note the positions.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

30 Remove the brake camshaft.

31 Remove the washer.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

32 Remove the dust cover.

33 Clean the contact surfaces carefully.

Note
Check for corrosion.

Note
Replace if necessary.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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34 Perform the same operation on the other side.

35 Install the dust cover.

Required material

HOLLOW DRIFT 9998225

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

36 Perform the same operation on the other side.

37 Remove the bushing and seal.

Note
Note the direction of assembly.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

A HANDLE 9992613

B MANDREL 9996298

38 Install the bushing.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

A HANDLE 9992613

B MANDREL 9998135

39 Install the seal.

Note
Respect the direction of assembly. The open side of the seal should face towards the
brake anchorage.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

A HANDLE 9992613

B MANDREL 9998135

40 Remove the screws.

41 Remove the protecting plate.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

42 Install the protecting plate.

43 Install the screws.

44 Torque tighten the screws.

Tightening torque

Protecting plate, screw 24 ±4 Nm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

45 Carefully clean the components.

46 Check the parts for wear and damage.

Note
Replace if necessary.

47 Install the washer.

48 Lubricate the sliding surfaces.

Required material

Universal grease

49 Install the brake camshaft.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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50 Check the parts.

Note
Replace if necessary.

51 Adjust the pressure screw assemblies.

Note
Tighten the nut (1) then loosen for 1 turn.
Tighten the nut (2) then loosen for 2 turns.
This procedure prevents the screws from being locked.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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52 Install the pressure pivots.

Note
Respect the positions.

53 Install the pressure screw assemblies.

Note
Respect the positions.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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54 Place the dust cover.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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55 Install the bellows.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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56 Clean the contact surfaces carefully.

Note
Check for corrosion.

57 Check the condition of the seal.

Note
Replace if necessary.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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58 Check the parts for wear and damage.

Note
Replace if necessary.

59 Lubricate the parts.

Note
Use only the type of grease that is included in the repair kit.

60 Install the pinion.

Note
Ensure that the teeth mesh correctly.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

61 Install the locking device.

Note
Check the lugs are correctly engage.

62 Install the spring.

63 Install the adjusting lever.

Required material

HOLLOW DRIFT 9994034

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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64 Install the toothed pin.

65 Install the gasket.

Note
Replace if necessary.

66 Install the cover.

67 Install the screws.

68 Torque tighten the screws.

Tightening torque

Adjustment mechanism, cover, screw 11 ±2 Nm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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69 Adjust if necessary.

Note
Turn the adjustment screw slightly so that the toothed pin and the pressure screw mesh
perfectly.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

70 Check the condition of the seal.

Note
Replace if necessary.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

71 Install the bracket.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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72 Install the screws.

73 Torque tighten the screws.

Tightening torque

Bracket, screw 125 ±15 Nm

74 Install the protection.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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75 Install the anchorage.

Note
Install as marked up.

76 Install the screws.

77 Torque tighten the screws.

Tightening torque

Brake anchorage, screw 1. M14 screw

160 ±20 Nm

2. M16 screw

225 ±20 Nm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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78 Install the bracket.

79 Install the screws.

80 Torque tighten the screws.

Tightening torque

Bracket, screw 125 ±15 Nm

81 Install the gasket.

Note
Use a new part.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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82 Install the brake lever.

Note
Install as marked up.

83 Install the screw and nut.

84 Torque tighten the screw and nut.

Tightening torque

Brake lever, screw 85 ±15 Nm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

85 Install the protection.

86 Install the clip.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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87 Install the brake anchorage.

Note
Install as marked up.

88 Install the nuts.

89 Torque tighten the nuts.

Tightening torque

Brake lever, screw 48 ±8 Nm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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90 Check the position of the fork.

Tech data

Brake lever, fork length (X1 – X2) 21 – 45 mm

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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91 Lubricate the brake cam bracket.

Required material

Universal grease

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.04.00 15/11/2024

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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