Brakes D-1
Page D-1
Section D
Brakes
ATTENTION
HSV vehicles are equipped with a Supplemental Restraint System (SRS). An SRS consists of seat belt pre-
tensioners (fitted to all front seat s), a driver’s-side air bag, a passeng er’s-side air bag and left and right h and
side air bags. Refer to CAUTIONS, Section 12M, in the Holden Cross 8 AWD series Service Manual 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.
1 Purpose...............................................................................................................................................D-2
2 General................................................................................................................................................D-3
3 HSV Avalanche AWD Performance Brake System .........................................................................D-4
4 Service Operations.............................................................................................................................D-7
4.1 Pad Replacement................................................................................................................................................D-7
4.2 Caliper Overhaul.................................................................................................................................................D-8
4.3 Brake Discs .........................................................................................................................................................D-9
Brake Disc Wear Limits......................................................................................................................................D-9
5 Service Parts.....................................................................................................................................D-10
Avalanche XUV AWD Performance Brake Replacement Parts.....................................................................D-10
Front Calipers................................................................................................................................................D-10
Rear Calipers ................................................................................................................................................D-11
Brakes D-2
Page D-2
1 Purpose
The purpose of this section is to provide information on the Brake Systems fitted to HSV Avalanche XUV AW D models.
Details are giv en where d ifferences occur be t ween the HSV m ode ls a nd standard Hol den models. A s er ies of instructio n
drawings describe the design changes and indicate specific part numbers, fitting instructions 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
Cross8 AWD series Service Information.
References are made throughout this section to
Holden Service Information to assist in providing
information for specific service operations.
When hoisting (or jacking) HSV models,
ensure that the lifting h ead of the hoist lifts on
the chassis before the arm of the hoist
contacts the side-skirt
Brakes D-3
Page D-3
2 General
Brake systems fitted to HSV Avalanche XUV AWD 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 wheels wh ich in turn, provides adequate braking (to the front or rear wheels) if a fault occurs in either system.
HSV Avalanche XUV AWD models are also equipped with the BOSCH Anti-lock Braking System (ABS) as standard.
Inspection, replacement and testing of the ABS must be carried out in accordance with the procedures detailed in the
relevant Holden Serv ice Manual. T he Av alanche br ake sys tem contains 336 x 32mm ‘AP Rac ing’ v entilated a nd gro oved
front discs, HSV embossed twin piston ‘Corvette’ front callipers in HRT red, 315 x 18mm ventilated and grooved rear
discs.
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
The Performance brake system has been developed by HSV and is a higher performance braking system than the
GMHA standard braking system. A description of this brake system is contained in succeeding paragraphs.
Brakes D-4
Page D-4
3 HSV Avalanche AWD Performance
Brake System
The new Avalanche XUV AWD Performance system - illustrated in Drawings 04I-030004 and 04I-030007 - 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 groov ed disc of 336mm x 32mm.
• Front Caliper Assemblies are twin piston floating of 40.5mm diameter.
• Bracket Caliper Mounting Brackets.
• Front Brake Hose (PN 05F-032701/2).
• Rear ventilated and grooved disc of 315mm x 18mm.
• Rear Caliper are single piston floating of 45mm diameter.
• Rear brake hose, (05F-97070 3).
• Pad material is JBI-NF42 HFF Front and BM962 Rear.
Brake Page D-5
Page D-5
advanced automotive design and engineering
RELEASE
REVISION RECORD
SYM
DATE
INSTRUCTION DRAWING.
advanced automotive design and engineering
SIGNATURES ON
ISSUE DATED
ORIGINAL APPROVAL
AUTH'YCK.
DR.
-
APPR
AVALANCHE
AP
D.P
26.02.04
APPR
CK.
DR.
MODEL :
DWG.
DATE:
REFERENCE :
PARTNO.
04I-030007
-
NAME
PERFORMANCE BRAKESYSTEM
FRONT
AVALANCHE
A4
SIZE
11.07.02 ECN. O1186.03
M.B
MAJOR ASSEMBLIES
1. 05A-040705/6
2. 05A-032701
3. 05F-032701/2
CALIPER ASM FRT. RH/LH
DISC FRONT PERFORMANCE
HOSE FRONT RH/LH
COMPONENTS / SERVICE PARTS
4. ABUTMENT BRACKET
5. PAD ABUTMENT SHIM
6. OUTER PAD ASM
7. INNER PAD ASM
8. BLEED SCREW COVER
9. BLEED SCREW
10. ANTI RATTLE SPRING
11. GUIDE PIN BOOT
12. CALIPER BODY
13. SEALING RING
14. PISTON BOOT
15. GUIDE PIN BOLT
16. GUIDE PIN
17. PISTON
2
1
3
4
#
#
1
2
3
4
5
6
7
89
10
11
12
13
14
15
16
17
3
2
1
32-37Nm
180 - 190 Nm
80-90NmTHEN 45° TURN
412-14NmTHEN 90° TURN
APPLYLOCTITE 243
#
BEFORE INSTALLATION
Brake Page D-6
Page D-6
advanced automotive design and engineering
RELEASE
REVISION RECORD
SYM
DATE
INSTRUCTION DRAWING.
advanced automotive design and engineering
SIGNATURES ON
ISSUE DATED
ORIGINAL APPROVAL
AUTH'YCK.
DR.
-
APPR
VY
L.H
D.P
22.04.03
APPR
CK.
DR.
MODEL :
DWG.
DATE:
REFERENCE :
PARTNO. 04I-030004
-
NAME
PERFORMANCE BRAKE
SYSTEM - REAR
A4
SIZE
11.07.02 ECN. O1186.03
M.B
3
2
1
70 - 100 Nm
32-37Nm
12-14Nm
APPLYLOCTITE 243
#
1
2
3
3
#
1
2
BEFORE INSTALLATION
MAJOR ASSEMBLIES
1. 05B-020709/10
2. 05B-000701
3. 05F-970703
CALIPER ASM RR RH/LH
DISC REAR PERFORMANCE
HOSE REAR BRAKE PERFORMANCE
Brake Page D-7
Page D-7
4 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.
4.1 Pad Replacement
Refer to appropriate dra wings in this section or in Holden S ervice Manual. Ensure that the following important n otes are
observed and repl ace brake pads in accorda nce with the procedures in the Holden Cross 8 AWD series Service Manual.
Important Notes On Brake P ad 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 Aval anche XUV AWD Performance brakes, ensure that shims and spring are fully clipped
into position so that they are clear of the rotor. Carefully lower the body over the pads and bracket ensuring the
pads are engaged with spring so that they are free to slide. Ensure Piston Boot is not caught between the Piston
and the inner pad. Fit new guide bolt through the lower hole and tighten to a torque of 30-34Nm.
Brake Page D-8
Page D-8
4.2 Caliper Overhaul
Refer to appropriate dra wings in this section or in Holden S ervice Manual. Ensure that the following important n otes are
observed and overhaul calipers as detailed in Section 5A-Standard Brakes of the Cross 8 AWD series Service
Information.
Notes On Caliper Overhaul
• Do not remove the mounting brackets unless damaged or for disc servicing.
• Remove the pistons by directing light air pressure into the brake hose port, and progressivel y increase until piston
is forced out of bore .
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.
Brake Page D-9
Page D-9
4.3 Brake Discs
Refer to appropriate dra wings in this section or in Holden Service Manual. Ensure that important notes are observed an d
overhaul discs as detailed in Section 5A-Standar d Brakes.
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 Holde n brakes is cast in the hub of the disc and is specified in
Section 5A – Standard Brakes in the Holden Service Manual. The minimum thickness for brake discs fitted to HSV brake
systems is stamped into the edge of the disc. For informa tion, the new and minimum thicknesses of discs used in HSV
brake systems are tabulated below.
Disc
Location
New
Thickness Minimum
Thickness
Avalanche AWD
Front 32.0mm 30.0mm
Rear 18.0mm 16.0mm
Brake Page D-10
Page D-10
5 Service Parts
It is essential that genuine replacement parts be fitted to HSV brake assemblies. This is particularly important 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.
Avalanche XUV AWD Performance Brake Replacement Parts
Refer to Drawings 04I-030007 and 04I-030004 for major component part numbers. Service kits for the Avalanche XUV
AWD Performance brake system are listed b elow:
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-040706 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
05A-040705 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
Brake Page D-11
Page D-11
05A-970733 PISTON BRAKE
05A-970734 BLEED SCREW
05A-970735 PAD ABUTM ENT SHIM
05A-970736 ANTI RATTLE SPRING
05A-970737 GUIDE PIN
05A-970738 GUIDE PIN BOLT
05A-040704 BRAKE PAD KIT JBI NF42 COMPRISING
2 OFF OUTER PAD ASSEMBLY JBI NF42 HFF
2 OFF INNER PAD ASSEMBLY JBI NF42 HFF
4 OFF GUIDE PIN BOLT
Rear Calipers
Servicing procedures and servicing kits for the Avalanche AWD Performance Rear Caliper are exactly the same as for
the standard Cross 8 AWD H olden Rear Cal iper. Therefore, when servici ng the Avalanche XUV AWD rear calip er, refer
to the procedures in the Section 5A- Standar d Brakes.
HSV Performance Rear Calipers use unique brake pads, with a thinner pad to suit HSV’s wider ventilated disc.
05B-020710 REAR CALIPER HOUSING ASSEMBLY RH COMPRISING
1 OFF CALIPER BODY
1 OFF SEALING RING
1 OFF CALIPER PISTON
1 OFF DUSTBOOT
1 OFF BLEED SCREW
1 OFF BLEED SCREW DUST CAP
05B-020709 REAR CALIPER HOUSING ASSEMBLY LH COMPRISING
1 OFF CALIPER BODY
1 OFF SEALING RING
1 OFF CALIPER PISTON
1 OFF DUSTBOOT
1 OFF BLEED SCREW
1 OFF BLEED SCREW DUST CAP
05B-970704 Rear Brake Pad Kit (BM962) COMPRISING
OFF BRAKE PAD (BM962)
4 OFF RETAINING BOLTS