SECTION D - BRAKES
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
passenge r’s-side a ir bag and right and left hand sid e air bag s. Refe r to CAUTIONS, Sect ion 12M , in the
Holden VS Series Service Manual or Section 12M of the VT Series II 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 syste m repairs.
PURPOSE
The purpose of this section is to provide information on the Brake Systems fitted to HSV VT2, WH and HSV VS
Models. This information is designed to supplement that given in the Holden VT Series II and VS Series Service
Inform ation, and details are given wher e differ ences occur between the HSV m odels a nd standard Holden m odels.
A series of ins truc tion dr awin gs desc rib e the des ign ch ange s an d ind icate s pec ific part numbers, f itting instruc tions
and relevant 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 – Standard Brakes of the VT Series II Service Information or the relevant section of the VS
Series Service Inform ation. References are made throughout this section to Ho lden Service I nformation, to assist
in providing information for specific service operations.
CAUTION: When hoisting (or jacking) HSV models, ensure that the lifting head of the hoist lifts on the chassis
before the arm of the hoist contacts the side-skirt
BRAKES
1. GENERAL
Brake systems fitted to HSV VT2 and HSV VS models employ the vacuum boosted, four-wheel-disc concept
operating through a tand em master cylinder. This tandem arrangement provides separate brak ing systems to the
front and rear wheels which in turn, provides adequate braking (to the front or rear wh ee ls ) if a fault occ urs i n ei ther
system. HSV VT2 and HSV VS models are also equipped with the BOSCH Anti-lock Braking System (ABS) as
standard. Inspection, replacem ent and testing of the ABS must be carried out in accordance with the procedures
detailed in the relevant Holden Service Manual.
CAUTION: Whenever any component of the ABS is disturbed during service operations, it is vital that the complete
ABS is checked using the procedure detailed in the relevant Holden Service Manual
Three alternate brak e s ystems ar e fitted t o HSV VT 2. Two of these s yst em s have been deve loped b y HS V, thes e
are higher performance braking systems. The other system used is the GMHA standard system fitted by Holden
during th e original v ehicle build-u p. A desc ription of thes e brake s ystem s and their Stan dard (S) and Optional (O)
application is contained in succeeding paragraphs.
TABLE D-1 BRAKE SYSTEMS
Model VT2
Premium VT2
Performance GMHA
VS GMHA*
VT
XU6
XU8
CLUBSPORT
SENATOR SEDAN
SENATOR WAGON
GRANGE
OO — S
CLUBSPORT R8 O S — —
SV99 S — — —
MALOO — — S —
GTS C4B S — — —
* From February the HSV GMHA braking system will upgrade to the Police Brakes
2. VT2 PERFORMANCE BRAKE SYSTEM
The new VT2 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 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 disc of 315mm x 18mm, (PN 05B 970701).
• Rear Caliper are single piston floating of 45mm diameter.
• Rear brake hose, (05F-970703).
• Pad material is JBINF-42 Front and BM962 Rear.
3. VT2 PREMIUM BRAKE SYSTEM
Components of the VT2 Premium are as follows:-
Note: VT2 Premium brakes system – illustrated in Figure D-3 and Figure D-4.
• Front ventilated and cross drilled Disc of 343mm x 32mm, ( PN 05A-970712)
• 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 (PN 05B-970701)
• 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. GMHA BRAKE SYSTEMS
The HSV Maloo Uti lity is fitted with Hold en brak es and these brak e system s are to be servic ed in accor dance with
the procedures in the relevant Holden Service Manual. In addition, the rear brake hose and the rear brake bias
valve linkage on the Maloo Utility must be adjusted as follows:
• Rear Brake Hose Retention. The rear brake hose is retained in position by a Herbie clip to ensure that
the hose doesn’t make contact wi th the exhaust system. This requirement is shown in Figure D-5.
• Rear brake b ias valv e linkage. T he Maloo 195 i Utilit y is equ ipped with a H SV design re ar brake bias
valve linkage assembly that operates in conjunction with the HSV specific panhard rod. It is designed
with a specific length li nkage nut to accom modate the lo wered ride he ight. The load sensing valve link
chain dimension must be measured before disconnecting the link chain for service. The link chain
assembly must be adjusted to maintain the previously measured dimension upon reassembly. Refer
Figure D-6.
CAUTION: IT IS CRITICAL FOR SAFETY THAT THE LINK CHAIN IS SET TO THE CORRECT
LENGTH AND THAT THE SPRING AND CLIP ARE CORRECTLY INSTALLED AS SHOWN IN
FIGURE D-5 AND FIGURE D-6.
6. SERVICE OPERATIONS
Although HSV brake systems have different fittings and components, the general service principles are the same
as those which apply to Holden standard brake systems. The important differences between Holden brake
systems and HSV systems are the component parts and the specified wear limits for those parts. Drawings of
specific HSV brake systems and component part numbers are included in this section and wear limits have also
been specified where required.
6.1. PAD REPLACEMENT
Refer to appropriate drawings in this section or in Holden Service Manual. Ensure that the following important
notes are observed and replace brake pads in accordance with the procedures in the Holden VT2 or VS series
Service Manual.
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 VT2 Performance brakes, ensure that shims and spring are fully clipped into
position so that the y are clear of the rotor. C aref ully lower the bo d y o ver th e pa ds an d brac ket ensuring t he
pads are engag ed with spring so that the y are free to slide. Ens ure Pis ton Boot is not caugh t betwe en the
Piston and the inner pad. Fit new guide bolt through the lower hole and tighten to a torque of 30-34Nm.
6.2 CALIPER OVERHAUL
Refer to appropri ate drawings in this sec tion or in Holde n Service Inf ormation. Ensure that the f ollowing im portant
notes are obser ved an d overh aul c alipers as detail ed in Section 5A - Standard Brakes of the VT Series I Service
Information or the VS Series Service Information.
NOTES ON CALIPER OVERHAUL
• Do not remove the mounting brackets unless damaged or for disc servicing.
• Remove the pis t ons by directing lig ht a ir pr ess ur e int o th e br ake hose port, and pr ogres s ively incr e as e un ti l
piston is forced out of bore .
CAUTION: Caution is necessary to avoid physical injury. Piston may be ejected with considerable force
due to air pressure. Use packing to prevent piston damaging body of caliper.
6.3 BRAKE DISCS
Refer to appropriate drawings in this section or in the appropriate Holden Service Information. Ensure that
important notes are observed and overhaul discs as detailed in Section 5A - Standard Brakes of the VT Series II
Service Information or the VS Series Service Information.
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
thickness for brake discs fitted to HSV brake systems is stamped into the edge of the disc. For information, the
new and minimum thicknesses of discs used i n HSV brake systems are tabulated below .
DISC
LOCATION NEW
THICKNESS MINIMUM
THICKNESS
VT2 PREMIUM
FRONT
REAR 32.0mm
18.0mm 30.0mm
16.0mm
VT2 PERFORMANCE
FRONT
REAR 32.0mm
18.0mm 30.0mm
16.0mm
6.4. SERVICE PARTS
It is essential that genuine replacement parts be fitted to HSV brake assemblies. This is particularly important
when replacin g brak e pads because of the various t ypes of linin g m aterial us ed. Com plete brak e ass emblies , fr ont
and rear discs, calipers and attachm ent 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.
VT2 Performance Replacement Parts
Refer to Figure D-1 and Figure D-2 for major component part numbers. Service kits for the VT2 Performance
brake system are listed below:
Front Calipers
05A-970730 FRONT HYDRAULIC REPAIR KIT COMPRISING
2 OFF SEAL ING 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 SEAL ING RING
2 OFF PISTON BOOT
2 OFF PISTON
1 OFF BLEED SCREW PROTECTOR COVER
1 OFF BLEE D 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 SEAL ING RING
2 OFF PISTON BOOT
2 OFF PISTON
1 OFF BLEED SCREW PROTECTOR COVER
1 OFF BLEE D 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-9707 34 BLEED SCR EW
05A-970735 PAD ABUTMENT SHIM
05A-970736 ANTI RATTLE SPRING
05A-9707 37 GUIDE PIN
05A-9707 38 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 VT2 Performance Rear Caliper are exactly the same as for the
standard VT2 Holden Re ar Caliper. T herefore, when servici ng the VT2 r ear caliper, ref er to the proc edures in the
Section 5A – Standa rd Brake s of the VT Series II Service Information.
HSV Performance 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.
VT2 Premium Replacement Parts
Refer to Figure D-3 and Figure D-4 for major component part num bers. Service kits for the VT2 Pr emium 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 BLEE D 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 BLEE D SCREW
2 OFF BLEED SCREW DUST CAP
05A-970720 PISTON 1 5/8
05A-970721 PISTON 1 ½
05A-9707 22 BLEED SCR EW
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 (PX1387) COMPRISING
4 OFF BRAKE PAD (PX1387)
Rear Calipers
05B-970713 REAR CALIPER HYDRAULIC REPAIR KIT COMPRISING
4 OFF SEAL ING 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 BLEE D 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 BLEE D SCREW
2 OFF BLEED SCREW DUST CAP
05B-970716 PISTON 1 1/8
05A-9707 22 BLEED SCR EW
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 (PX1387) COMPRISING
4 OFF BRAKE PAD (PX1387) REAR