SECTION D - BR AKES
CAUTION:
HSV vehicles are equipped with a Supplemental Restraint System (SRS). An SRS consists of seat belt pre-
tensioners (fitted to all front seats), and a driver’s-side air bag or a driver’s-side air bag AND a passenger’s-
side air bag and right and left hand side air bags. Refer to CAUTIONS, Section 12M, of the Holden VX
Series Service Information before performing any service operation on or around SRS components, the
steering mechanism or wiring. Failure to follow the CAUTIONS could result in personal injury or
unnecessary SRS system repairs.
PURPOSE
The purpos e of this sec tion is t o prov ide i nform ation on th e Br ake S ystem s fitted to HSV VX & W H m odels. Deta ils
are given where differences occur between the HSV models and standard Holden models. A series of instruction
drawings descr ibe the design c hanges and i ndicate s pec ific par t num bers, fitting i nstr uctions a nd re levant notes for
vehicle servicing.
NOTE:
If specific technical data on a HSV model is not contained in this supplement, obtain data for that model from
Section 5A – Standa rd Brakes of the VX series Service Information. References are made throughout this section
to Holden Service Information to assist in providing information for specific service operations.
CAUTION:
W hen hoisting (or jac king) HSV models , ensure that the lifting h ead of the hoist lifts on the chass is before the arm
of the hoist contacts the side-skirt
1. BRAKES - GENERAL
Brake systems fitted to HSV VX and WH models employ the vacuum boosted, four-wheel-disc concept operating
through a tandem master cylinder. This tandem arrangement provides separate braking systems to the front and
rear whee ls which in turn, provides ad equate brak ing (to the f ront or rear whee ls) if a fault occurs in either syst em.
HSV VX and WH models are also equipped with the BOSCH Anti-lock Braking System (ABS) as standard.
Inspection, replacement and testing of the ABS m ust be carried out in accordance with the procedures detailed in
the relevant Holden Service Information.
CAUTION: Whenever any com ponent of the ABS is d i s tur bed duri ng s ervice operatio ns, it is vit al tha t th e complete
ABS is checked using the procedure detailed in the relevant Holden Service Information.
Three alternate brake systems are fitted to HSV VX. Two of these systems have been developed by HSV, these
are higher performance braking systems. The other system used is the GMHA standard system fitted by Holden
during the original vehicle build-up. A description of these brake systems and their Standard (S) and Optional (O)
application is contained in succeeding paragraphs.
TABLE D-1 BRAKE SYSTEMS
Model VX
Premium VX
Performance GMHA*
VX
XU6
CLUBSPORT
SENATOR SEDAN
SENATOR WAGON
GRANGE
O
O
S*
S*
S*
S
S
CLUBSPORT R8
GTS O
STD S
- –
–
* These models use the GMHA Police Brake Package.
2. VX PERFORMANCE BRAKE SYSTEM
The new VX Performance system - illustrated in Figure D-1 and Figure D-2, is a further development of brake
systems developed for earlier HSV models. The major components of the new Performance System are as follows:
• Front ventilated and grooved disc of 330mm x 32mm.
• Front Caliper Assemblies are twin piston floating of 40.5mm diameter.
• Bracket Caliper Mounting Brackets, (PNs LH 05A-970713, RH 05A-970714).
• Front Brake Hose (PN 05F-970706/7).
• Rear ventilated and grooved disc of 315mm x 18mm.
• Rear Caliper are single piston floating of 45mm diameter.
• Rear brake hose, (05F-970703).
• Pad material is JBINF-42 Front and BM962 Rear.
3. VX PREMIUM BRAKE SYSTEM
Components of the VX Premium are as follows:-
Note: VX Premium brakes system – illustrated in Figure D-3 and Figure D-4.
• Front ventilated and cross drilled Disc of 343mm x 32mm.
• Front four piston opposed Caliper Assembly - 2 pistons of 38.1mm and 2 pistons of 41.3mm diameter.
• Front brake hose (PN 05F-970706/7).
• Rear ventilated and cross drilled brake disc 315mm X 18mm
• Rear four piston opposed Caliper Assembly with piston size of 28.57mm diameter.
• Pad material is PX1387, front and rear.
• Rear brake hose (PN 05F-970704).
4. SE R VICE OP ERATIONS
Although HSV brake systems have different fittings and components, the general service principles are the same
as those whic h app ly to H ol den s ta ndar d brake systems . The im por tant dif f er enc es between Ho ld en brak e systems
and HSV s ystem s are the component parts and the spec ified wear lim its for thos e parts. Dr awings of specifi c HSV
brake systems and component part numbers are included in this section and wear lim its have also been specified
where required.
4.1. PAD REPLACEMENT
Refer to appropriate drawings in this section or in Holden Service Inform ation. Ensure that the following important
notes are observed and replace brake pads in accordance with the procedures in the Holden VX Series Service
Information.
IMPORTANT NOTES ON BRAKE PAD REPLACEMENT
• Do not remove mounting brackets unless damaged or for disc servicing.
• Pads should be replaced if there is less than 3mm of lining material remaining or if pads are damaged.
• Pads must be replaced as a full set of 4. Ensure pad material is correct specification. Do not mix pad
material front to rear. Use genuine HSV replacement parts to ensure correct pad material is used.
• Before fitting new pads check that all pads are fitted with insulating material.
• When replacing pads in VX Performance brakes, ensure that shims and spring are fully clipped into
position s o that th ey are c lear of the rotor. Careful ly lower the bod y over the pads and brack et ensur ing the
pads are engaged with spri ng so that th ey are free t o slide. E nsure Pist on Boot is not c aught bet ween the
Piston and the inner pad. Fit new guide bolt through the lower hole and tighten to a torque of 30-34Nm.
4.2 CALIPER OVERHAUL
Refer to appropriate drawings in this section or in Holden Service Inform ation. Ensure that the following important
notes are observed and overhaul calipers as detailed in Section 5A - Standard Brakes of the VX Series Service
Information.
NOTES ON CALIPER OVERHAUL
• Do not remove the mounting brackets unless damaged or for disc servicing.
• Remove the pistons by dire cting light air press ure int o the brak e hose port, and pr ogress ivel y increase until
piston is forced out of bore .
CAUTION:
Caution is necessary to avoid physical injur y - Piston may be ejected with considerable force due to air pressure.
Use packing to prevent piston damaging body of caliper.
4.3 BRAKE DISCS
Refer to appropriate drawings in this section or in Holden Service Information. Ensure that important notes are
observed and overhaul discs as detailed in Section 5A - Standard Brakes.
CAUTION:
Do not remove mounting bracket from the brake caliper unless the bracket requires service. It is critical for safety
that the bolts holding the mounting bracket to the caliper if removed, are correctly reinstalled.
Brake Disc Wear Limits. The minimum thickness for discs fitted to standard Holden brakes is cast in the hub of
the disc and is specified in Section 5A – Standard Brakes in the Holden Service Information. The minimum
thick ness for brak e dis c s fitted to HSV br ak e systems is stam ped into the edge of the dis c . For inf or mation, th e ne w
and minimum thicknesses of discs used in HSV brake systems are tabulated below.
Disc
Location New
Thickness Minimum
Thickness
VX Premium
Front 32.0mm 30.0mm
Rear 18.0mm 16.0mm
VX Performance
Front 32.0mm 30.0mm
Rear 18.0mm 16.0mm
4.4. SERVICE PARTS
It is essential t hat gen ui ne r epl ac ement parts be f itted t o HS V br ak e as s emblies . This is part ic ul arly im portant when
replacing brake pads because of the various types of lining material used. Complete brake assemblies, front and
rear discs, calipers and attachment parts have also been identified as replacement parts and these items are
available from HSV: these parts are listed in the following paragraphs or referenced in enclosed drawings.
VX PERFORMANCE REPL ACEMENT PARTS
Refer to Figure D-1 and Figure D-2 for m aj or c om ponent part number s . Ser vic e kits f or the VX Perf or mance br ak e
system are listed below:
Front Calipers
05A-970730 FRONT HYDRAULIC REPAIR KIT COMPRISING
2 OFF SEALING RING
2 OFF PISTON BOOT
1 OFF BLEED SCREW PROTECTOR COVER
2 OFF GUIDE PIN BOOT
05A-970731 FRONT CALIPER HOUSING ASSEMBLY RH COMPRISING
1 OFF CALIPER BODY RH
1 OFF ABUTMENT BODY
2 OFF PAD ABUTMENT SHIM
2 OFF SEALING RING
2 OFF PISTON BOOT
2 OFF PISTON
1 OFF BLEED SCREW PROTECTOR COVER
1 OFF BLEED SCREW
1 OFF ANTI RATTLE SPRING
2 OFF GUIDE PIN BOOT
2 OFF GUIDE PIN
2 OFF GUIDE PIN BOLT
O5A-970732 FRONT CALIPER HOUSING ASSEMBLY LH COMPRISING
1 OF CALIPER BODY LH
1 OFF ABUTMENT BODY
2 OFF PAD ABUTMENT SHIM
2 OFF SEALING RING
2 OFF PISTON BOOT
2 OFF PISTON
1 OFF BLEED SCREW PROTECTOR COVER
1 OFF BLEED SCREW
1 OFF ANTI RATTLE SPRING
2 OFF GUIDE PIN BOOT
2 OFF GUIDE PIN
2 OFF GUIDE PIN BOLT
05A-970733 PISTON BRAKE
05A-970734 BLEED SCREW
05A-970735 PAD ABUTMENT SHIM
05A-970736 ANTI RATTLE SPRING
05A-970737 GUIDE PIN
05A-970738 GUIDE PIN BOLT
05A-990704 BRAKE PAD KIT JBI NF42 COMPRISING
2 OFF OUTER PAD ASSEMBLY JBI NF42
2 OFF INNER PAD ASSEMBLY JBI NF42
4 OFF GUIDE PIN BOLT
Rear Calipers
Servicing procedures and servicing kits for the VX Performance Rear Caliper are exactly the same as for
the standard VX Holden Rear Caliper. Therefore, when servicing the VX rear caliper, refer to the
procedures in the Sect ion 5A- Standard Brake s.
HSV Perform ance Rear Calipers use unique brake pads, with a thinner pad to suit HSV’s wider ventilated
disc. The Rear Brake Kit details are 05B-970704 Brake Pad Kit BM962.
VX PREMIUM REPLACEMENT PARTS
Refer to Figure D-3 and Figure D-4 for major component part numbers. Service kits for the VX Premium brake
system are listed below:
Front Calipers
05A-970717 FRONT CALIPER HYDRAULIC REPAIR KIT COMPRISING
2 OFF SEALING RING 1 5/8
2 OFF SEALING RING 1 ½
4 OFF DUSTBOOT
4 OFF DUSTBOOT RETAINING RING
2 OFF BLEED SCREW DUST CAP
2 OFF CALIPER BRIDGE SEAL
05A-970718 FRONT CALIPER HOUSING ASSEMBLY RH COMPRISING
1 OFF CALIPER BODY -INNER HALF RH
1 OFF CALIPER BODY -OUTER HALF RH
2 OFF SEALING RING 1 5/8
2 OFF SEALING RING 1 ½
2 OFF CALIPER PISTON 1 5/8
2 OFF CALIPER PISTON 1 ½
4 OFF DUSTBOOT
4 OFF DUSTBOOT RETAINING RING
1 OFF PAD RETAINER
2 OFF CALIPER BRIDGE SEAL
2 OFF PAD WEAR STRIP RH
4 OFF PAD WEAR STRIP SCREW
2 OFF PAD WEAR STRIP LH
4 OFF CALIPER BOLTS
1 OFF PAD RETAINING BOLT
2 OFF BLEED SCREW
2 OFF BLEED SCREW DUST CAP
05A-970719 FRONT CALIPER HOUSING ASSEMBLY LH COMPRISING
1 OFF FRONT CALIPER BODY - INNER HALF LH
1 OFF FRONT CALIPER BODY OUTER HALF LH
2 OFF SEALING RING 1 5/8
2 OFF SEALING RING 1 ½
2 OFF CALIPER PISTON 1 5/8
2 OFF CALIPER PISTON 1 ½
4 OFF DUSTBOOT
4 OFF DUSTBOOT RETAINING RING
1 OFF PAD RETAINER
2 OFF CALIPER BRIDGE SEAL
2 OFF PAD WEAR STRIP RH
4 OFF PAD WEAR STRIP SCREW
2 OFF PAD WEAR STRIP LH
4 OFF CALIPER BOLTS
1 OFF PAD RETAINING BOLT
2 OFF BLEED SCREW
2 OFF BLEED SCREW DUST CAP
05A-970720 PISTON 1 5/8
05A-970721 PISTON 1 ½
05A-970722 BLEED SCREW
05A-970723 PAD RETAINER
05A-970724 CALIPER BOLT
05A-970725 PAD RETAINER BOLT
05A-970726 PAD WEAR STRIP RH
05A-970727 PAD WEAR STRIP LH
05A-970728 PAD WEAR STRIP SCREW
05A-990729 BRAKE PAD KIT (BM1387) COMPRISING
4 OFF BRAKE PAD (BM1387)
Rear Calipers
05B-970713 REAR CALIPER HYDRAULIC REPAIR KIT COMPRISING
4 OFF SEALING RING
4 OFF DUSTBOOT
4 OFF DUSTBOOT RETAINING RING
2 OFF BLEED SCREW DUST CAP
2 OFF CALIPER BRIDGE SEAL
05B-970714 REAR CALIPER HOUSING ASSEMBLY RH
COMPRISING
1 OFF CALIPER BODY -INNER HALF RH
1 OFF CALIPER BODY -OUTER HALF LH
4 OFF SEALING RING 1 1/8
4 OFF CALIPER PISTON 1 1/8
4 OFF DUSTBOOT
4 OFF DUSTBOOT RETAINING RING
1 OFF PAD RETAINER
2 OFF CALIPER BRIDGE SEAL
2 OFF PAD WEAR STRIP RH
2 OFF PAD WEAR STRIP LH
4 OFF PAD WEAR STRIP SCREW
4 OFF CALIPER BOLTS
1 OFF PAD RETAINING BOLT
2 OFF BLEED SCREW
2 OFF BLEED SCREW DUST CAP
05B-970715 REAR CALIPER HOUSING ASSEMBLY LH
COMPRISING
1 OFF CALIPER BODY -INNER HALF RH
1 OFF CALIPER BODY -OUTER HALF LH
4 OFF SEALING RING 1 1/8
4 OFF CALIPER PISTON 1 1/8
4 OFF DUSTBOOT
4 OFF DUSTBOOT RETAINING RING
1 OFF PAD RETAINER
2 OFF CALIPER BRIDGE SEAL
2 OFF PAD WEAR STRIP RH
2 OFF PAD WEAR STRIP LH
4 OFF PAD WEAR STRIP SCREW
4 OFF CALIPER BOLTS
1 OFF PAD RETAINING BOLT
2 OFF BLEED SCREW
2 OFF BLEED SCREW DUST CAP
05B-970716 PISTON 1 1/8
05A-970722 BLEED SCREW
05B-970717 PAD RETAINER
05B-970718 CALIPER BOLT
05B-970719 PAD RETAINER BOLT
05B-970720 PAD WEAR STRIP RH
05B-970721 PAD WEAR STRIP LH
05B-970728 PAD WEAR STRIP SCREW
05B-990722 BRAKE PAD KIT (BM1387) COMPRISING
4 OFF BRAKE PAD (BM1387) REAR