🔧 XC60 - Rear Brake and Rotor Replacement

The rear brakes on your XC60 use an electronic parking brake, so the rear caliper must be put into service mode before you can retract it safely. This job includes replacing the rear pads and rotors, then resetting the parking brake system after assembly.

Difficulty Level: Intermediate | Estimated Time: 2-4 hours

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⚠️ Safety & Precautions

• Rear brakes are tied to the electronic parking brake. Put the system in service mode before compressing the caliper.
• Use jack stands. Never work under a vehicle supported only by a jack.
• Brake parts can be hot after driving. Let everything cool first.
• Do not press the brake pedal with the caliper or pads removed.
• Brake dust is harmful. Avoid blowing it off with compressed air.
• Battery disconnect is not usually required, but ignition should be off unless using the scan tool.

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🔧 Required Tools

You'll need the following tools for this repair:

• Floor jack (rated 3-ton minimum)
• Jack stands (2 minimum)
• Wheel chocks
• Breaker bar
• 19mm socket
• Torx T30 screwdriver
• Torx T40 screwdriver
• 13mm socket
• 14mm wrench
• Ratchet
• Torque wrench
• C-clamp or disc brake piston tool
• Trim tool
• Wire brush
• Bungee cord or mechanics wire
• Brake cleaner
• Safety glasses
• Nitrile gloves
• Scan tool with electronic parking brake service function (specialty)

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Rear brake pad set - Qty: 1
• Rear brake rotors - Qty: 2
• Rear pad hardware kit - Qty: 1
• Brake grease - Qty: 1
• Brake cleaner - Qty: 1

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📋 Before You Begin

• Park on level ground and set wheel chocks at the front wheels.
• Keep the ignition off until you are ready to use the scan tool.
• Put the electronic parking brake into service mode with the scan tool before removing the calipers.
• Work on one side at a time so you can use the other side as a reference.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Prepare the vehicle

• Use the floor jack to lift the rear of the XC60 and support it with jack stands.
• Remove both rear wheels using the 19mm socket and breaker bar.
• Break loose lug bolts before lifting.

Step 2: Put the parking brake in service mode

• Use the scan tool with electronic parking brake service function to retract the rear parking brake system.
• Follow the scan tool prompts until the system confirms service mode.
• Menu path: Scan Tool > Chassis > Parking Brake > Service Mode

Step 3: Remove the rear caliper

• Use the Torx T40 screwdriver to remove the caliper guide bolts.
• Lift the caliper off the bracket and hang it with a bungee cord or mechanics wire.
• Do not let the caliper hang from the brake hose.
• Keep the hose relaxed and untwisted.

Step 4: Remove the old pads and hardware

• Remove the old brake pads from the bracket.
• Use the trim tool to remove any pad clips or retaining springs.
• Clean the bracket contact points with wire brush and brake cleaner.

Step 5: Remove the caliper bracket

• Use the 13mm socket and ratchet to remove the caliper bracket bolts.
• Remove the bracket from the knuckle.
• Torque on installation: Torque to 105 Nm (77 ft-lbs).

Step 6: Remove the rotor

• Use the Torx T30 screwdriver to remove the rotor retaining screw.
• Pull the rotor off the hub.
• If it sticks, tap the rotor hat lightly and use penetrating force by hand only on the rotor face.
• Clean the hub face with wire brush and brake cleaner.
• A clean hub prevents rotor runout.

Step 7: Install the new rotor

• Clean the new rotor with brake cleaner before installation.
• Install the new rotor onto the hub.
• Install the rotor retaining screw with the Torx T30 screwdriver.

Step 8: Reinstall the caliper bracket

• Install the caliper bracket using the 13mm socket and ratchet.
• Torque to 105 Nm (77 ft-lbs).

Step 9: Install the new pads and compress the caliper

• Apply a small amount of brake grease to the pad contact points and slide areas.
• Install the new pad hardware and pads.
• Use the C-clamp or disc brake piston tool to slowly compress the rear caliper piston.
• Make sure the piston goes in smoothly and stays square.
• Go slow to avoid seal damage.

Step 10: Reinstall the caliper

• Place the caliper over the new pads.
• Install the guide bolts using the Torx T40 screwdriver.
• Torque to 35 Nm (26 ft-lbs).

Step 11: Repeat on the other side

• Perform the same rotor and pad replacement steps on the opposite rear wheel.

Step 12: Reinstall wheels and lower the vehicle

• Reinstall both wheels and start the lug bolts by hand.
• Use the 19mm socket to snug the bolts in a star pattern.
• Lower the vehicle and torque the lug bolts with the torque wrench.
• Torque to 140 Nm (103 ft-lbs).

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✅ After Repair

• Use the scan tool to exit parking brake service mode.
• Press the brake pedal several times until it feels firm.
• Apply and release the parking brake to confirm normal operation.
• Test drive at low speed and check for noise, vibration, or pulling.
• For the first 200 miles, avoid hard braking so the pads can bed in.

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💰 DIY vs Shop Cost

Shop Cost: $450-$850 (parts + labor)

DIY Cost: $180-$380 (parts only)

You Save: $270-$470 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 2-4 hours.

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🎯 Ready to get started?

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