Brakes Page 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 seats), a d river’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, of the Holden Adventra AWD 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 repa irs.

1 Purpose...................................................................................................................................................2

2 Brakes......................................................................................................................................................3

2.1 General Information............................................................................................................................................... 3

2.2 HSV Avalanche AWD Performance Brake System.............................................................................................. 4

2.3 Service Operations................................................................................................................................................ 7

Pad Replacement................................................................................................................................................... 7

Important Notes On Brake Pad Replacement .................................................................................................... 7

2.4 Caliper Overhaul.................................................................................................................................................... 8

2.5 Brake Discs ............................................................................................................................................................ 9

Brake Disc Wear Limits......................................................................................................................................... 9

2.6 Service Parts........................................................................................................................................................ 10

Avalanche AWD Performance Brake Replacement Parts ................................................................................ 10

Front Calipers................................................................................................................................................... 10

Rear Calipers ................................................................................................................................................... 11

Brakes Page D-2

Page D-2

1 Purpose

The purpose of this section is to provide information on the Brake S ystems fitted to HSV Avalanche AWD models. Details

are given where differenc es occur between the HSV models and standard Holden models. A series of instruction

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

Holden Adventra 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 o f th e hoist lifts on

the chassis before the arm of the hoist

contacts the side-skirt

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2 Brakes

2.1 General Information

Brake systems fitted to HSV Avalanche AWD models employ the vacuum boosted, four-wheel-disc con cept operating

through a tandem master cylinder. This tand em arrangement provides separate braking systems to the front and rear

wheels which in turn, provides adequate braking (to the front or rear wheels) if a fault occurs in either system. HSV

Avalanche AWD models are also eq uipped with the BOSCH Anti-lock Braking S ystem (ABS) as standard. Inspection,

replacement and testing of the ABS must be carried out in accordance with the procedures detailed in the relevant

Holden Service Information. The Aval anche brake system cont ains 336 x 32mm ‘AP Racing’ ventilated and grooved front

discs, HSV embossed twin piston ‘Corvette’ front calli pers 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 Information.

The Performance brake system has been developed by HS V and is a higher performance braking system than the

GMHA standard braking system. A description of this brake system is contained in succeeding paragr aphs.

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2.2 HSV Avalanche AWD Performance Brake

System

The new Avalanche AWD Performance system - illustrated in Drawings 04I-030007 and 04I-030004 is a further

development of brake s ystems devel oped for earlier HSV models. The major com ponents of the new Performance

System are as follows:

• Front ventilated and grooved 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 d isc of 315mm x 18mm.

• Rear Caliper are single piston floating of 45mm diameter.

• Rear brake hose, (05F-970703).

• Pad material is JBI-NF42 HFF Fr ont and BM962 Rear.

Brakes Page D-5

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advanced automotive design and engineeringadvanced automotive design and engineering

RELEASE

REVISION RECORD

SYM

DATE

INSTRUCTION DRAWING.INSTRUCTION DRAWING.

advanced automotive design and engineeringadvanced automotive design and engineering

SIGNATURES ONSIGNATURES ON

ISSUE DATEDISSUE DATED

ORIGINAL APPROVALORIGINAL APPROVAL

AUTH'YAUTH'Y CK.

DR.

APPR

AVALANCHE

D.P

26.02.04

APPR

CK.

DR.

MODEL :

DWG.DWG.

DATE:

REFERENCE :

PART NO.

04I-030007

NAME

PERFORMANCE BRAKESYSTEM

FRONT

AVALANCHE

SIZE

11.07.02 ECN. O1186.03

ECN. O1186.03

M.B

MAJOR ASSEMBLIES

1. 05A-040705/61. 05A-040705/6

2. 05A-0327012. 05A-032701

3. 05F-032701/23. 05F-032701/2

CALIPER ASM FRT. RH/LHCALIPER ASM FRT. RH/LH

DISC FRONT PERFORMANCEDISC FRONT PERFORMANCE

HOSE FRONT RH/LHHOSE FRONT RH/LH

COMPONENTS / SERVICE PARTSCOMPONENTS /SERVICE PARTS

4. ABUTMENT BRACKET

5. PAD ABUTMENT SHIM

6. OUTER PAD ASM6. OUTER PAD ASM

7. INNER PAD ASM7. INNER PAD ASM

8. BLEED SCREW COVER8. BLEED SCREW COVER

9. BLEED SCREW9. BLEED SCREW

10. ANTI RATTLE SPRING10. ANTI RATTLE SPRING

11. GUIDE PIN BOOT11. GUIDE PIN BOOT

12. CALIPER BODY12. CALIPER BODY

13. SEALING RING13. SEALING RING

14. PISTON BOOT14. PISTON BOOT

15. GUIDE PIN BOLT15. GUIDE PIN BOLT

16. GUIDE PIN16. GUIDE PIN

17. PISTON17. PISTON

32-37Nm

32 -37 Nm

180 - 190 Nm180 -190 Nm

80 - 90 Nm THEN 45° TURN80 -90 Nm THEN 45° TURN

412 - 14 Nm THEN 90° TURN

12 -14 Nm THEN 90° TURN

APPLY LOCTITE 243APPLY LOCTITE 243

BEFORE INSTALLATIONBEFORE INSTALLATION

Brakes Page D-6

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advanced automotive design and engineeringadvanced automotive design and engineering

RELEASE

REVISION RECORD

SYM

DATE

INSTRUCTION DRAWING.INSTRUCTION DRAWING.

advanced automotive design and engineeringadvanced automotive design and engineering

SIGNATURES ONSIGNATURES ON

ISSUE DATEDISSUE DATED

ORIGINAL APPROVALORIGINAL APPROVAL

AUTH'Y CK.

DR.

APPR

L.H

D.P

22.04.03

APPR

CK.

DR.

MODEL :

DWG.

DATE:

REFERENCE :

PART NO.

04I-030004

NAME

PERFORMANCE BRAKE

SYSTEM - REAR

SIZE

11.07.02 ECN. O1186.03

ECN. O1186.03

M.B

70 - 100 Nm

70 -100 Nm

32-37Nm32 -37 Nm

12-14Nm12 -14 Nm

APPLY LOCTITE 243APPLY LOCTITE 243

BEFORE INSTALLATIONBEFORE INSTALLATION

MAJOR ASSEMBLIES

1. 05B-020709/101. 05B-020709/10

2. 05B-0007012. 05B-000701

3. 05F-9707033. 05F-970703

CALIPER ASM RR RH/LHCALIPER ASM RR RH/LH

DISC REAR PERFORMANCEDISC REAR PERFORMANCE

HOSE REAR BRAKE PERFORMANCEHOSE REAR BRAKE PERFORMANCE

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Page D-7

2.3 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.

Pad Replacement

Refer to appropriate dra wi ngs 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 Adventra AWD series Service

Information.

Important Notes On Brake Pad Replacemen t

• Do not remove mounting brackets unless damaged or for disc servicing.

• Pads should be replaced if there is less than 3mm of lining material r emaining 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 replaceme nt parts to ensure correct pad material is used.

• Before fitting new pads check that all pads are fitted with insulati ng material.

• When replacing p ads in Avalanche AWD Performance brak es, ensure that shims and spring are fully c lipped

into position so that they are clear of the roto r. Carefully lower the body over the pads and brack et 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 ne w guide bolt through the lo wer hole an d tighten to a torque of 30-34Nm.

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2.4 Caliper Overhaul

Refer to appropriate dra wi ngs 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 Holden Adventra AWD series

Service Information.

Notes On Caliper Overhaul

• Do not remove the mounting brackets unless damaged or for disc servicin g.

• Remove the pistons by directing light air pre ssure into the brake h ose p ort, and progressively incr ease 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.

Brakes Page D-9

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2.5 Brake Discs

Refer to appropriate dra wings in this section or in Holden S ervice Information. Ensure tha t important notes are o bserved

and overhaul discs as detaile d in Section 5A-Standard Brak es.

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 Adventra AWD series 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 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

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2.6 Service Parts

It is essential that genuine replacement parts be fitted to HSV brake assemblies. This is particularly imp ortant when

replacing brake pads beca use of the various types of linin g 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 ref erenced in enclosed drawings.

Avalanche AWD Performance Brake Replacement Parts

Refer to Drawings 04I-030007 and 04I-030004 for major component part numbers. Service kits for the Avalanche AWD

Performance brake system ar e listed below:

Front Calipers

05A-970730 FRONT HYDRAULIC REPAIR KIT COMPRISING

2 OFF SEALING RING

2 OFF PI STON 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 PI STON BOOT

2 OFF PI STON

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 PI STON BOOT

2 OFF PI STON

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

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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 Holden Adventra AWD series Service Information Rear Caliper. Therefore, when servicing the Avalanche

AWD rear caliper, refer to the procedures in the Section 5A- Standard Brakes.

HSV Performance Rear Calipers use uniq ue 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

4 OFF BRAKE PAD (BM962)

4 OFF RETAINING BOLTS