Brakes Page D–1
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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), 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 VY 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..
1 Purpose................................................................................................................................................... 2
1.1 General....................................................................................................................................................................2
1.2 Load Sensing Proportioning Valve.......................................................................................................................3
2 HSV Performance Brake System.......................................................................................................... 5
3. HSV Premium Brake System................................................................................................................ 8
4 HSV 6 Piston Brake System Components ........................................................................................ 11
5. Service Operations.............................................................................................................................. 14
5.1. Pad Replacement .................................................................................................................................................14
5.2 Caliper Overhaul...................................................................................................................................................15
5.3 Brake Discs...........................................................................................................................................................16
Brake Disc Wear Limits .......................................................................................................................................16
5.4. Service Parts.........................................................................................................................................................17
VY Performance Replacement Parts ..................................................................................................................17
Front Calipers...................................................................................................................................................17
Rear Calipers....................................................................................................................................................18
VY Premium Replacement Parts.........................................................................................................................19
Front Calipers...................................................................................................................................................19
Rear Calipers....................................................................................................................................................20
VY HSV 6 Piston Replacement Parts..................................................................................................................22
Front Brakes.....................................................................................................................................................22
Rear Brakes......................................................................................................................................................22
Brakes Page D–2
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1 Purpose
The purpose of this section is to provide information on the Brake Systems fitted to HSV VY models. Details are given
where differences 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
MY 2003 VY and V2 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 head of the hoist lifts on
the chassis before the arm of the hoist
contacts the side-skirt
1.1 General
Brake systems fitted to HSV VY 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 which
in turn, provides adequate braking (to the front or rear wheels) if a fault occurs in either system. HSV VY 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 Service Information. Refer to
Section 5B - ABS & ABS/TCS in the MY 2003 VY and V2 Series Service Information.
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
Three brake systems are fitted to HSV VY. These systems have been developed by HSV and are a higher performance
braking system than the GMHA standard braking system. A description of the brake systems and their Standard (S) and
Optional (O) application is contained in succeeding paragraphs.
Table D-1 Brake Systems
Model Peformance Premium AP Racing
CLUBSPORT
CLUBSPORT R8
MALOO
MALOO R8
SENATOR SEDAN
SENATOR SIGNATURE
GTS
S
S
S
O
S
O
S
O
S
S
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1.2 Load Sensing Proportioning Valve
The HSV VY Utility series models braking system differs from the HSV Sedan models, with the addition of a load sensing
proportioning valve, which is coupled to the rear suspension and therefore the deletion of the standard master cylinder
proportioning valve.
For full details, refer to the Holden VY Service Information, Section 5A Brakes. HSV VY models have lower suspension
than the Holden models and have a unique HSV proportioning valve cable fitted to maintain brake balance. This unique
proportioning valve cable is shorter than the Holden part. Refer to Instruction Drawing 05I-010001.
HSV Part Name: Cable – Proportioning Valve
HSV Part Number: 05B-010501
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Brakes Page D–5
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2 HSV Performance Brake System
The new VY Performance Brake System, illustrated in Drawings 04I-030003 and 04I-030004, is a f u rth e r de ve lo pm en t o f
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.
• 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.
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Brakes Page D–7
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Brakes Page D–8
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3. HSV Premium Brake System
Components of the VY Premium Brake System, illustrated in Drawings 04I-030005 and 04I-030006 are as follows:
• 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 BM1387, front and rear.
• Rear brake hose (PN 05F-970704).
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Brakes Page D–10
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Brakes Page D–11
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4 HSV 6 Piston Brake System
Components
Components of the HSV 6 Piston Braking System package, illustrated in Drawings 04I-030001 and 04I-030002 are as
follows:
• Front ventilated and cross drilled Disc of 362mm x 32mm.
• Front six piston opposed Caliper Assembly - 2 leading pistons of 27.0mm, 2 intermediate pistons of 31.75mm
diameter, and 2 trailing pistons of 33.1mm diameter.
• Front brake hose (PN 05F-970706/7).
• Rear ventilated and cross drilled brake disc 343mm X 26mm.
• Rear four piston opposed Caliper Assembly with piston size of 38.1mm diameter.
• Pad material is Ferodo DS2500, front and rear.
• Rear brake hose (PN 05F-970704).
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Brakes Page D–13
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Brakes Page D–14
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5. 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.
5.1. Pad Replacement
Refer to appropriate drawings in this section or in Holden Service Information. Ensure that the following important notes
are observed and replace brake pads in accordance with the procedures in the MY 2003 VY and V2 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 VY 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 30-34 N.m.
• When replacing pads in the HSV 6 Piston Braking System, ensure the pad retaining pins are driven fully into
position.
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5.2 Caliper Overhaul
Refer to appropriate drawings in this section or in Holden Service Information. Ensure that the following important notes
are observed and overhaul calipers as detailed in Section 5A Standard Brakes of the MY 2003 VY and V2 Series Service
Information.
NOTES ON CALIPER OVERHAUL
• Do not remove the mounting brackets unless
damaged or for disc servic ing.
• Remove the pistons by directing light air
pressure into the brake hose port, and
progressively 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.
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5.3 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 of the MY 2003 VY and V2 Series Service Information.
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 of the MY 2003 VY and V2 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
VY Premium
Front 32.0mm 30.0mm
Rear 18.0mm 16.0mm
VY Performance
Front 32.0mm 30.0mm
Rear 18.0mm 16.0mm
AP Racing
Front 32.0mm 30.0mm
Rear 26.0mm 24.0mm
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5.4. 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.
VY Performance Replacement Parts
Refer to Drawings 04I-030003 and 04I-030004 for major component part numbers. Service kits for the VY Performance
brake 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-030702 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-030701 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
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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 VY Performance Rear Caliper are exactly the same as for the standard
VY Holden Rear Caliper. Therefore, when servicing the VY rear caliper, refer to the procedures in the Section 5A
Standard Brakes of the MY 2003 VY and V2 Series Service Information.
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
4 OFF BRAKE PAD (BM962)
4 OFF RETAINING BOLTS
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VY Premium Replacement Parts
Refer to Drawings 04I-030005 and 04I-030006 for major component part numbers. Service kits for the VY 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-020712 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-020711 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
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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-020712 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
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05B-020711 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
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VY HSV 6 Piston Replacement Parts
Refer to Drawings 04I-030001 and 04I-030002 for major component part numbers. Service kits for the VY HSV 6 Piston
system are listed bel ow:
Front Brakes
05A-021211 1 OFF DISC – FRT BRAKE LH – ALUM/HAT
05A-021212 1 OFF DISC – FRT BRAKE RH – ALUM/HAT
05A-021205 1 OFF CALIPER ASM FRT – LH – NO PADS
05A-021206 1 OFF CALIPER ASM FRT – RH – NO PADS
05A-021209 1 OFF PAD PACKAGE FT – FERODO DS2500
05A-021202 2 OFF SERVICE KIT – FRT CALIPER 6 PISTON
05F-970707 1 OFF HOSE – FRONT BRAKE – LH
05F-970706 1 OFF HOSE – FRONT BRAKE – RH
05F-970705 4 OFF GASKET – BRAKE HOSE – COPPER
05A-000714 4 OFF BOLT – FRT CALIPER TO KNUCKLE
Rear Brakes
05B-021211 1 OFF DISC – RR BRAKE LH – VENTED/C
05B-021212 1 OFF DISC –RR BRAKE RH – VENTED/C
05B-021205 1 OFF CALIPER ASM – RR – LH NO PADS
05B-021206 1 OFF CALIPER ASM – RR – RH NO PADS
05B-021209 1 OFF PAD PACKAGE – RR- FERODO DS2500
05B-021202 2 OFF SERVICE KIT – RR CALIPER 4 PISTON
05F-970704 2 OFF HOSE – REAR BRAKE – PREMIUM
05F-970705 4 OFF GASKET – BRAKE HOSE – COPPER
71A-970702 4 OFF WASHER – FLAT – ID 12, T 1.5m
05B-000714 4 OFF BOLT – REAR CALIPER TO KNUCKLE