Xc60 brake calipers (2015)
 

My wifes XC60 R Design brakes felt a bit spongy so i decided to bleed them, they aren't in the best condition (corrosion) but the pads are nearly new. I bled all the brakes but when i got to the last one (front drivers) the bleed nipple snapped. I soaked them all in WD40 before hand and applied some heat to the caliper and they all bled ok except the last. I couldn't get the nipple out with an extractor either and as the calipers were badly corroded i ordered two good corrosion free (relatively) from a 2014 XC60. When they arrived i noticed the replacement calipers are two pot where mine are single piston. The replacement has a bigger footprint and being two pot calipers i thought they'd be an upgrade as they are the same fitment. I stripped them down and cleaned and wire brushed for painting and bought stainless braded hoses and stainless bleed nipples for all 4 calipers. The front right bleed nipple sheared off on the new one despite the lubrication and heat :speechless-smiley-4
Is it worth trying to get it drilled out and maybe oversized bleed nipples or are the original calipers better anyway? Why did volvo change from two piston to one anyway?

Personally I wouln't faff around with second hand parts when it comes to braking. Autodoc or eurocarfarts would be a better option for parts.


Getting a like for like new would be better piece of mind rather than drilling out potentially knackered parts. Plus you would guarantee that they would fit.
Your parts mismatch would be either an ATE or a TRW caliper, but I could be wrong. I would look at the brand on your broken caliper and order accordingly. Just an "XC60 caliper" would yield a number of things. Bigger engine size, bigger disc, bigger caliper. You may have had a higher performing engine's caliper sent to you, which in turn would have been a bigger disc. Your footprint of pad on the disc would not be the same as the part of the car it came off.

Brake component swaps warrant replacement of discs, carriers and calipers all in one, (Been there done that).

I do use second hand parts but would seriously draw the line on braking components. It'd be like fitting a second hand timing belt...