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Section 5A

Service and Park Braking Systems

ATTENTION

Before performing any Service Operation or other procedure described in this Section, refer to Section 00

Warnings, Cautions and Notes for correct workshop practices with regard to safety and/or property damage.

1 General Information ...............................................................................................................................4

1.1 General Description............................................................................................................................................... 4

1.2 Master Cylinder...................................................................................................................................................... 5

Description............................................................................................................................................................. 5

Construction........................................................................................................................................................... 5

Operation................................................................................................................................................................ 6

1.3 Vacuum Brake Booster ......................................................................................................................................... 7

Description............................................................................................................................................................. 7

Construction........................................................................................................................................................... 7

Operation................................................................................................................................................................ 7

Mechanical Brake Assist (MBA)......................................................................................................................... 7

1.4 Front and Rear Brake Calipers ............................................................................................................................. 8

1.5 Brake Pipes and Hoses ......................................................................................................................................... 9

Description............................................................................................................................................................. 9

2. Minor Service Operations..........................................................................................................................10

2.1 Service Warnings, Cautions and Notes............................................................................................................. 10

2.2 Park Brake Cable, Adjust.................................................................................................................................... 12

2.3 Brake Fluid Level Check ..................................................................................................................................... 13

2.4 Brake System Bleed ............................................................................................................................................ 14

2.5 Brake Fluid, Change............................................................................................................................................ 15

Draining Master Cylinder .................................................................................................................................... 15

Draining Brake Calipers ...................................................................................................................................... 16

2.6 Brake Pad Wear, Check....................................................................................................................................... 17

Front or Rear........................................................................................................................................................ 17

2.7 Brake Pads, Replace............................................................................................................................................ 18

Preparation........................................................................................................................................................... 18

Front Brake Pads................................................................................................................................................. 19

Remove............................................................................................................................................................ 19

Installation........................................................................................................................................................ 20

Rear Brake Pads .................................................................................................................................................. 21

Remove............................................................................................................................................................ 21

Reinstall ........................................................................................................................................................... 22

Brake Pad Bedding-In Procedure....................................................................................................................... 22

2.8 Brake Pedal Assembly.............................................................................................................................................. 23

Remove................................................................................................................................................................. 23

Disassemble......................................................................................................................................................... 26

Reassemble.......................................................................................................................................................... 26

Reinstall................................................................................................................................................................ 27

2.9 Park Brake Lever.................................................................................................................................................. 28

Remove................................................................................................................................................................. 28

Reinstall................................................................................................................................................................ 29

2.10 Park Brake Warning Lamp Switch...................................................................................................................... 30

Remove................................................................................................................................................................. 30

Inspect .................................................................................................................................................................. 30

Reinstall................................................................................................................................................................ 31

Techline

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2.11 Front Park Brake Cable ....................................................................................................................................... 32

Remove................................................................................................................................................................. 32

Reinstall................................................................................................................................................................ 32

2.12 Rear Park Brake Cable/s ..................................................................................................................................... 34

Remove................................................................................................................................................................. 34

Reinstall................................................................................................................................................................ 35

2.13 Front Caliper Brake Hose.................................................................................................................................... 36

Remove................................................................................................................................................................. 36

Reinstall................................................................................................................................................................ 37

2.14 Rear Caliper Brake Hose..................................................................................................................................... 39

Remove................................................................................................................................................................. 39

Reinstall................................................................................................................................................................ 39

2.15 Rear Brake Hoses................................................................................................................................................ 40

Remove................................................................................................................................................................. 40

Reinstall................................................................................................................................................................ 41

2.16 Brake Booster Hose & Valve Assembly – V6 Engine........................................................................................ 42

Replace................................................................................................................................................................. 42

2.17 Brake Booster Hose & Valve Assembly – GEN III V8 Engine........................................................................... 43

Replace................................................................................................................................................................. 43

2.18 Brake Fluid Level Switch..................................................................................................................................... 44

Test ....................................................................................................................................................................... 44

Replace................................................................................................................................................................. 44

3 Major Service Operations....................................................................................................................45

3.1 Master Cylinder.................................................................................................................................................... 45

Remove................................................................................................................................................................. 45

Reinstall................................................................................................................................................................ 46

3.2 Brake Master Cylinder Reservoir........................................................................................................................ 47

Replace................................................................................................................................................................. 47

3.3 Brake Booster ...................................................................................................................................................... 48

Remove................................................................................................................................................................. 48

Reinstall................................................................................................................................................................ 49

3.4 Front Brake Caliper.............................................................................................................................................. 50

Remove................................................................................................................................................................. 50

Disassemble......................................................................................................................................................... 51

Clean and Inspect................................................................................................................................................ 52

Reassemble.......................................................................................................................................................... 52

Reinstall................................................................................................................................................................ 54

3.5 Rear Brake Caliper............................................................................................................................................... 55

Remove................................................................................................................................................................. 55

Disassemble......................................................................................................................................................... 55

Clean and Inspect................................................................................................................................................ 57

Reassemble.......................................................................................................................................................... 57

Reinstall................................................................................................................................................................ 59

3.6 Front Brake Disc.................................................................................................................................................. 60

Remove................................................................................................................................................................. 60

Inspect .................................................................................................................................................................. 61

Front Brake Disc and Hub Indexing Procedure................................................................................................. 63

Part 1. Clean Mating Surfaces ......................................................................................................................... 63

Part 2. Indexing Brake Disc to Hub .................................................................................................................. 63

Part 3. Hub Runout Check ............................................................................................................................... 64

Reinstall................................................................................................................................................................ 65

3.7 Rear Brake Disc ................................................................................................................................................... 66

Remove................................................................................................................................................................. 66

Inspect .................................................................................................................................................................. 67

All Models......................................................................................................................................................... 67

Rear Brake Disc and Hub Indexing Procedure.................................................................................................. 68

Part 1 Clean Mating Surfaces .......................................................................................................................... 68

Part 2 Indexing Brake Disc to Hub ................................................................................................................... 69

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Part 3 Trunnion Hub Runout Check ................................................................................................................. 70

Reinstall................................................................................................................................................................ 70

3.8 Park Brake Lining Wear, Check.......................................................................................................................... 71

3.9 Park Brake Shoe, Adjust ..................................................................................................................................... 72

3.10 Park Brake Shoe .................................................................................................................................................. 74

Remove................................................................................................................................................................. 74

Reinstall................................................................................................................................................................ 75

3.11 Front Disc Brake Shield ...................................................................................................................................... 77

3.12 Rear Disc Brake Dust Shield............................................................................................................................... 78

Remove................................................................................................................................................................. 78

Reinstall................................................................................................................................................................ 80

4. Diagnosis ..............................................................................................................................................82

5 Specifications.......................................................................................................................................83

6 Torque Wrench Specifications............................................................................................................85

7 Special Tools ........................................................................................................................................86

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1 General Information

1.1 General Description

Some illustrations in this Section may show components that are not fitted to all vehicles. Where differences in service

procedures apply, then relevant information relating to those differences are made.

All MY2005 WL Series vehicles are fitted with a Stepped Tandem, Vacuum Suspended type brake booster and a 26 mm

bore master cylinder. Neither the master cylinder nor the brake booster serviceable and m ust be replaced if proven to be

defective.

There are a number of different master cylinders that eac h have unique characteristics to suit the ap plication intended.

Therefore, should a master cylinder ne ed to be replaced, then the correct assembly for that applicati on must be fitted.

Refer to the current Partfinder™ parts catalogue for the correct replacement.

All MY2005 WL Series vehicles are fitted with ventilated discs at the front and solid discs at the rear. The brake ca lipers

are the sliding, reaction type, with twin pistons in the front calipers and a singl e in the rear.

The front disc brake caliper is attached to the steering knuckle support by two bolts, while the front wheel bearing hub

attaches to the steering knuckle, using three bolts. The front dust shield is also attached to the steering knuckl e support

by three pop rivets.

The rear brake backing plate assemb ly is bolted to the trailing arm, as is the disc brake caliper. The machined inner

surface of the disc hub acts as the brake drum for the park brake.

The single shoe, Banksia design park brake is a drum type with a manual adj ustment incorporated into the design. The

park brake is operated by a cable at the rear, connected to an equaliser bracket. Park brake application force is applied

to this equaliser bracket, via a singl e cable, connected to the floor mounted, button release, park brake lever. Adjustment

of the parking brake cables on all W L mod els is provided for, by a threaded end on the front, single cable, at the park

brake lever end.

For a description and servicing information relating to the Anti-lock Brakin g System (ABS), Traction Control (TC),

Electronic Stability Program (ESP), Electroni c Brake Assist (EBA) and/or Electronic Brake Distribution (EBD) s ystems,

refer to Section 5B ABS / TCS /ESP – General Information where direction to specific information on any of these

systems, is detailed.

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1.2 Master Cylinder

Description

A tandem master cylinder with a 26 mm diameter bore is used on all MY 2 005 WL Series vehicles, regardless of the

braking system. There are however, unique differences in design, with a br ief summary being:

a An ABS type master cylinder has two pipes connected to the ABS hydraulic modulator; one for the front brakes

(primary) and the other (secondar y) for the rear.

b For those MY 2005 WL Series vehicles fitted with Electronic Brake Assist (EBA) and Electronic Stabi lity Program

(ESP), the master cylinder has unique internal valving to optimise the effect of these features.

c No vehicle in the MY 2005 WL model range has a brake proportioning valve. Front to rear braking balance is

achieved by electronic control from the ABS module (referred to as ‘Electronic Brake Differential – EBD), through

the hydraulic modulator.

It is vital that the correct replacement master cylinder is fitted to any MY 2005 WL Series vehicle. Refer to the current

release of PartFinder™ for the correct part.

Construction

This tandem, centre valve design master cylinder is attached to the vacuum brake booster, which is mounted to the

engine side of the dash panel. The master cylinder provides separate hydraulic circuits for the application of the brakes,

in a front (primary) to rear (secondary) split arrangement.

Both of these circuits are fed by separate flui d feed through a common fluid reservoir (3), that has a se al (2) fitted inside

the reservoir cap (1). This seal provides an effective seal against any atmospheric moisture comi ng into contact with the

hygroscopic brake fluid. This provision maintains the brake fluid's boiling point, for a maximum period of time.

The internal parts of the alumi nium a lloy master cylinder comprise a primary piston (19) supported by a gui de bush and

O-ring (22), with a recuperation seal (17) and a secondary piston (15) incorporating a ce ntre valve (12), a caged spring

(11), a recuperation (14) and an L t ype seal (15), a return spring (9) and a piston stop pin (6). The master cylinder bore is

anodised and is not to be hon ed.

An O-ring seal (24) is fitted to the master cylinder mounting flange, to provi de a vacuum seal between the master

cylinder and the vacuum susp ended brake booster.

Figure 5A – 1 – Typical Exploded View of Brake Master Cylinder

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Legend

1 Reservoir Cap

2 Reservoir Cap Seal

3 Brake Fluid Reservoir

4 Fluid Level Switch

5 Sealing Grommets

6 Cylinder Pin

7 Master Cylinder Body

8 Reservoir Retaining Screw

9 Return Spring

10 Centre Valve Sleeve

11 Centre Valve Spring

12 Centre Valve Plunger and Seal

13 Secondary Piston

14 Secondary Recuperating Seal

15 L Type Primary Seal

16 Return Spring and Retainer

17 Primary Recuperating Seal

18 Washer

19 Primary Piston

20 Primary Piston Support Washer

21 Vacuum Seal

22 Primary Piston Guide Bush and O-ring

23 Circlip

24 O-ring Seal

Operation

When the brake pedal is depressed, force is applied by mechanical linkage to the vacuum suspen ded brake booster.

Vacuum assisted force is then applied to the primar y and secondary master cylinder pistons. As the pis t ons are stroked

in the master cylinder bore, the developed hydraulic pressure is used to apply the front and rear disc brakes.

Once the brake pedal is released, the primary and secondary springs return the pistons to the released position and

brake fluid returns to the reservoir.

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1.3 Vacuum Brake Booster

Description

The brake booster is designed to reduce th e force required to develop the required brake fluid pressure, necessary to

apply the front and rear brakes.

Construction

There are no serviced components within the brake booster (2) assembly and, if found to be faulty, the complete unit

must be replaced. A sealing gasket (1) is positioned between the booster and the instrument panel that is used to both

seal the connection and to dampen noise transfer.

A one-way vacuum valve (4) is fitted to the front casing of the booster assembly, secured by a grommet (3). This non-

return valve is used to maintain the vacuum suppl y in the brake booster for a limited number of brake applications,

should an emergency situ ation occur, such as engine failure.

The barcode label attached to the front of the booster provides the booster part number and build data (e.g. month, day,

year, shift, line number). Check the current release of PartFinder™ for the correct part number for the vehicle requiring

the part.

Figure 5A – 2

Legend

1 Sealing Gasket

2 Vacuum Booster Assembly 3 Sealing Grommet

4 One-way Valve

Operation

When the brake pedal is depressed, movement of the booster input rod controls the opening and closing of internal

valving, allowing atmospheric pressure to enter one side of a diaphragm. With engine vacuum always present on the

other side, the pressure difference provides the required assistance in the movement of the master cylin der pistons and

the application of the brakes.

Mechanical Brake Assist (MBA)

The Mechanical Brake Assist (MBA) feature results from a mecha nical, two stage valving design within the brake

booster, that provides a dual reaction ratio, which has the effect of assisting the driver to reach ABS braking threshold

more easily. To assist in an emergency situation, MBA produces a quick booster response and reduces pedal effort

without affecting the pedal 'feel'.

MBA however, will change the brake peda l feel above a 0.5 to 0.6 g deceleration a nd is a feature of all vacuum boosters ,

fitted to MY 2005 WL Series vehicles with ABS or ABS/TC.

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1.4 Front and Rear Brake Calipers

The front and rear brake calip er assemb lies are common for all braking systems available for the MY 2005 WL Series

range of vehicles. An exploded view of the twin piston front caliper is shown in Figure 5A-3.

For the front brakes, the anchor plate is rigidly fi xed to the steering knuckle support arm, while the housing slides within

the anchor plate by means of t wo guide p ins bolted to the housing. Rubber boots are fitted to the guide pins to exclude

moisture, dirt and foreign matter.

The rear brake caliper anchor plates are bolted to the trailing arm and also have a floating housing, sliding over two

guide pins that are fitted with rubber dust boots.

The housing incorpor ates either twin (front) or a single hydraulic piston (rear), each with a seal. When hydrau lic pressure

is applied, the piston forces the inner pad ag ainst the disc and the reaction of the housi ng pulls the outer pad against the

disc. The forces of the pads on each side of the disc are therefore equal.

When the hydraulic pressure is released, the piston seal/s retracts the piston/s a small amount, allowing the moving parts

to relax sufficiently for the pads to remain in close proximity to the disc without dragging. Adjustment for wear is

automatic.

Refer to 2.7 Brake Pads Replace, in this Section, for further informati on regarding brake pad application.

Figure 5A – 3 – Front Brake Caliper – All WL Models

Legend

1 Caliper Housing

2 Bleed Screw

3 Self Locking Bolt (2 places)

4 Guide Pin (2 places)

5 Guide Pin Boot

6 Anchor Plate

7 Clip ( 2 places)

8 Outer Brake Pad

9 Inner Brake Pad

10 Piston Boot (2 places)

11 Piston (2 places)

12 Cylinder Seal (2 places)

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1.5 Brake Pipes and Hoses

Description

Except for the one difference detailed here, the brake pipe arran gement carries over from earlier models.

For those WL vehicles fitted with the Electronic Stabilit y Program (ESP), the brake pi pe diameter is increased to 6.35 mm

to increase fluid flow for the ESP System. The pipe fitting for the primary front and the rear brake pipes are both 12 mm

at the master cylinder.

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2. Minor Service Operations

2.1 Service Warnings, Cautions and Notes

ATTENTION

All fasteners are important attaching parts as they affect the performance of vital components and/or could

result in major repair expense. W here specified in this section, fasteners MUST be replaced w ith parts of the

same part number or an approved equivalent. Do not use fasteners of an inferior quality or substitute d esig n.

Torque values must be used as specified during reassembly to ensure proper retention of all components.

Throughout this section, fastener torque wrench specifications may be accompanied with the following

identification marks:

 Fasteners must be repl aced after loosening.

 Vehicle must be at curb height before final tightening.

 Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock and

should only be re-used once. If in doubt, replacement is recommended.

If one of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

Brake Pads

• While genuine Holden wheel brake parts are not asbestos based in their material composition, a

danger exists that no n-g en uine parts replacement may contain asbestos.

NOT ONLY IS IT IN THE INTERESTS OF PERSONAL SAFETY BUT ALSO THE SAFE AND

RELIABLE OPERATION OF THE BRAKING SYSTEM, THAT ONLY GENUINE PARTS ARE USED

FOR REPLACEMENT PURPOSES.

• When servicing wheel brake parts, do not create dust by grinding or sanding brake linings, by

cleaning wheel brake parts with a dry brush or with compressed air. Breathing in dust that may

contain asbestos fibres can cause serious bodily harm over a lengthy time period.

A water dampened cloth or water based solution should be used to remove any dust on brake

parts. Equipment is commercially available to perform this washing function. These wet methods

prevent brake component fibres from becoming airborne.

Brake Fluid

• The polyglycol brake fluid used in MY 2005 WL Series vehicles is hygroscopic and absorbs

moisture from the air through th e brake hoses etc. The boi ling resistance o f the fluid decreas es as

the moisture content increases and so the possibility of a vapour lock under heavy braking

conditions increases with the age of the fluid. Therefore, for maximum brake effecti veness, a two

yearly change of b rake flu id is mandatory, refer to 2.5 Brake Fluid Change, in this Section.

• To prevent the absorption of moisture from the air or other contamination, it is recommended that

the brake fluid be stored in small (500 ml) containers and that any surplus fluid remaining in a

container after use be di scard ed.

• The only approved brake fluid is Super DOT 4 Plu s and is a vailable in 250 and 500 ml cont ainers. If

pressure bleed ing equipmen t is used, it must be of an appro ved type w ith a diap hragm separating

the brake fluid from the air.

• Brake fluid is extremely damaging to paint. If fluid should accidentally come into contact with a

painted surface, immediate ly wash the fluid fro m th e paint and clean the painted surface.

ABS/TC Components

• Whenever any component that forms part of the ABS is disturbed during any service operation, it

is vital that the complete ABS system be checked, refer to Section 5B, ABS/TCS/ESP – General

Information.

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Road Wheels

• Whenever a road wheel and/or brake rotor is removed from or installed to a MY 2005 WL Series

vehicle, it MUST be done in accordance with the recommended procedure, refer to

Section 10 Wheels and Tyres.

• Whenever a road w heel and/or brake di sc is removed from the vehicle, the relationship of the road

wheel and the disc to the hub MUST be marked with a felt tipped pen or similar, to allow those

parts to be reinstalled in their original positions. This is critical to minimise the brake disc and

road wheel runout dimension.

• When reinstalling road wheels, do not use

an impact gun to tighten wheel nuts

unless the impact gun is fitted with a

torque limiter socket (Tool No. AU 534 or

a commercial equivalent). Failure to

correctly tighten w heel nuts to the correct

torque specification and in the correct

order (as shown), may result in a

distorted brake disc, leading to the

development of brake shudder.

Road wheel attaching nut

torque specification....................................110 – 140 Nm

For a complete description of the method used to

measure both brake disc and trunnion assembly runout

and correction, refer to 3.6 Front Brake Disc or

3.7 Rear Brake Disc, in this Section.

Figure 5A – 4

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2.2 Park Brake Cable, Adjust

1 Raise rear of vehicle and support on jack sta nds under

each lower control arm, to maintain the correct

suspension attitude.

2 Loosen the park brake cable a djustme nt nut several

turns.

3 Apply the park brake until the lever is extended 4 – 6

clicks.

4 Using a dial type torque wrench and a deep socket,

tighten the cable adjustment nut (arro w) until a torque

of 2 Nm is applied.

5 Check that this adjustment applies the park brake

shoes to a firm drag torque, by turning each rear

wheel.

NOTE

• With a new par k brake i nstallation or one that

has the correct park brake shoe adjustment,

the thread on the front cable should protrude

through the adjustment nut by 15 – 20 mm.

• If the park brake cannot be satisfactorily

adjusted by the above method, it will be

necessary to refer to 3.9 Park Brake Shoe,

Adjust, in this Section.

Figure 5A – 5

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2.3 Brake Fluid Level Check

Check that the fluid level is between the MIN and MAX level

markings on the translucent reservoir housing.

NOTE

If the fluid is between the markings, do not

remove reservoir cap, as brake fluid exposed to

the atmosphere will quickly absorb moisture.

Should the addition of fluid be required, wipe the sides of

the reservoir cover clean, then unclip and remove the

reservoir cap. Top up fluid using heavy duty brake fluid that

complies with Super DOT 4 Plus.

Figure 5A – 6

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2.4 Brake System Bleed

LT Section No. – 04-725

Do not re-use any brake fluid discharged

during the bleeding process.

Remove air from other components of the brake s ystem as follows:

1 Remove master cylinder reservoir cap (1) and fit a

commercially availabl e pressure bleed cap.

Figure 5A – 7

2 Connect cap to pressure bleed pump and pressurise system to no more than 345 kPa.

3 Open brake bleeder of line to be ble d and pump brake pedal one stroke/secon d for approximately 10 strokes, then

close bleeder. During this operation the pressure bleeder to the master cylinder should not be turned off. It is

essential that this volume and rate of flow is maintained to ensure air trap ped in pipes is carried out of the system

with the flow of the fluid and not allowed to retreat between strokes of the brake pedal.

4 At the conclusion of the brake bleedin g process, check that all dust caps are installed to the brake bleeder valves.

NOTE

View A shows the brake bleeder location for the

front brake caliper, while view B is for the rear.

Figure 5A – 8

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2.5 Brake Fluid, Change

ATTENTION

The following fasteners MUST be replaced when performing these operations:

 Brake caliper to trailing arm attaching bolts.

Draining Master Cylinder

Brake fluid will cause damage to the paint

work. If contact does occur, immediately

wash the brake flui d o ff with water.

1 Thoroughly cle an master cylinder, especially around wheel brake line connections.

2 Disconnect wheel brake lines (1) from master cylinder

(2), then remove reservoir cap (3).

3 Allow master cylinder to drain into a container until

empty.

4 Fill master cylinder reservoir with fresh, specified

brake fluid from a sealed 500 ml container and ensure

reservoir is maintained at least half full for remain der

of procedure.

5 Allow fluid to flow from open connection ports until

fluid is free of air. Collect discharged fluid in a suitable

container and then discard. Do not allow fluid to

contact paintwork.

6 Reinstall the brake lines (1) to master cylinder (2) and

tighten to specified torque.

Brake pipe to master cylinder

flare nut torque specification.................................14 Nm

Figure 5A – 9

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Draining Brake Calipers

1 Raise the vehicle and suppor t in a safe manner. Refer

to Section 0A General Information for the location of

recommended lifting and support points.

2 Mark position of wheels relative to hub a nd remove

wheels.

3 Loosen the left hand front caliper bleed screw (bold

arrow, in 'A', Figure 5A – 8).

4 Remove front left hand caliper anchor plate retaining

bolts.

5 Hold caliper upside d own and remove bleed scre w to

drain contents of caliper into suitable rece ptacle.

6 Hand tighten bleed screw and reinsta ll caliper

assembly, using NEW bolts.

7 Tighten caliper anchor p late retaining bolts to specified

torque.

() Front brake caliper anchor plate

bolt torque specification........................................85 Nm

plus 45° turn angle

Figure 5A – 10

8 Repeat steps 2 to 7 for the other front caliper and the rear caliper assemblies. Note that a different toque

specification applies to the rear caliper attaching bolts.

9 Tighten the rear brake caliper anchor plate bolts to the correct torque specificatio n.

Rear brake caliper anc hor

bolt torque specification........................................85 Nm

10 Bleed brake system, refer to 2.4 Brake System Bleed, in this Section.

11 Reinstall road wheel in original pos ition and lower vehicle.

12 Tighten road wheel nuts in a ' s tar' pattern, to the specified torque. Refer to 2.1 Service Warnings, Cautions and N otes,

in this Section.

Road wheel attaching

nut torque specification.............................110 – 140 Nm

13 Road test the vehicle to ensure correct brake operation.

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2.6 Brake Pad Wear, Check

Front or Rear

NOTE

The procedure and minimum thickness

specification is common to both front and rear

brake pads, despite the fact that only the front

brake caliper procedure is provided.

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information in this Service Information

for the location of recommended lifting and supp ort points.

2 Remove rear decorative wheel nut caps.

3 Mark the relationship of the road wheel to hub or brake rotor. Loosen, then remove the road wheel attaching nuts,

working in a 'star' pattern. Refer to 2.1 Service Warnings, Cautions and Notes, in this Section.

4 Remove the pads to be checked, from the caliper

ensuring that the original pad positions are noted.

Refer to 2.7 Brake Pads, Replace, in this Section.

5 Using vernier calipers, check the brake pa d thickness

in the four locations shown. The min imum lining

thickness should be no less that the thickness

specified. Also, pad wear should be even – if not, then

the cause must be established and corrected.

Brake pad minimum lining

thickness before replacement............................ 2 mm

6 If not being replaced, reinstall the brake pads in

the same locations, prior to removal. Refer to

2.7 Brake Pads, Replace, in this Section, for the

required procedures for this operati on. Figure 5A – 11

7 Reinstall road wheel and secure with the wheel nuts but do not fully tighten.

8 Lower the vehicle to the ground an d tighten the wheel nuts to the specified torque, working in a star pattern, refer to

2.1 Service Warnings, Cautions and Notes, in this Section.

Road wheel attaching nut

torque specification...................................110 – 140 Nm

9 Reinstall decorative wheel nut caps.

10 Road test vehicle to ensure correct brake operatio n.

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2.7 Brake Pads, Replace

LT Section No. – 04-750 and 04-825

ATTENTION

The following fastener has micro-encapsulated sealant applied to the threads and should be replaced () on

reassembly:

 Brake caliper gui de pin bolts.

Preparation

NOTE

This 'Preparation' stage is common for the front

or rear brake pad replacemen t.

• Do not completely remove the brake line,

nor empty the reser voir. If this does occur,

complete bleeding of the braking system,

will be necessary.

• Do not attempt to re-use the removed fluid.

• Brake fluid will damage paint-work.

1 Unscrew the master cylinder reservoir cap.

2 Using a hand vacuum pump (1), Tool No. J23738-A or

a commercially available eq uivalent or syringe,

remove fluid from the reservoir (2) until it is

approximately half full.

NOTE

Hold the brake fluid level float down with the

suction tube, during this operation.

3 Reinstall the reservoir cap.

NOTE

Removal of fluid from the reservoir is needed to

stop reservoir overflow when caliper piston is

pushed back in its bore during pad rep lacement.

Figure 5A – 12

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Front Brake Pads

Remove

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information in this Service Information

for the location of recommended lifting and supp ort points.

2 Remove the wheel cover or the decorative wheel nut caps, then mark the relationship of the road wheel to one of

the wheel studs.

3 Loosen, then remove the road wheel attaching nuts, working in a 'star' pattern. Refer to

2.1 Service Warnings, Cautions and Notes, in this Section.

4 Using G-clamps as shown, tighten until the caliper

pistons bottom in each bore.

Figure 5A – 13

5 Using a suitable size open end spanner to hold the

lower guide pin, remove and discard the guide pin bolt.

NOTE

Old bolts must not be re-used, as they are vital

safety components which have a micro-

encapsulated adhesive on the bolt threa d.

6 Swing caliper assembly up from the anchor plate and

disc. Support caliper with a wire hook.

7 Remove worn pads from anchor plate.

8 Inspect condition of brake disc.

9 Check guide pins for free movement in the anchor

plate. If there is restriction of movement, replace

guide pins and/or guide pi n boots. Refer to

3.4 Front Brake Caliper, in this Section.

10 Clean any dirt from both the piston face, which

contacts the inner pad, and the caliper head area

which contacts the outer pad. Figure 5A – 14

11 Install new brake pads as follows:

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Installation

1 Thoroughly cle an both piston contact faces, using a suitable solve nt such as Prepsol™, if required.

2 Install the outer pad to the caliper, noting that a leg of the steel spring should sit on top of the inner pad.

3 Reinstall the brake caliper h ousing, ensuring that the outer spring clip e ng ages with the middle finger of the caliper

housing.

4 Install and tighten a NEW guide pin self locking bolt to the correct torque specification.

 Brake caliper guide pin

bolt torque specification........................................32 Nm

NOTE

• Use a suitable open end spanner to prevent

the guide pin from rotating when tightening

the guide pin bolt.

• Do not wedge anything bet ween the guide pi n

hex and the caliper as it could cause incorrect

alignment of the pin which would then restrict

the free sliding of the caliper relative to the

anchor plate.

5 Fill master cylinder to correct level with fresh, brake fluid of the correct specification.

6 Depress and hold the brake pedal down in the app lied position for at least 5 seconds, to ensure that the inner pads

stick to the pistons.

7 Refill master cylinder if neces sary.

8 Reinstall wheels, aligning marks made prior to removal and lower vehicle to the ground.

9 Tighten road wheel attaching nuts to the specified torque, working in a star pattern, as detailed in

2.1 Service Notes and Cautions, in this Section.

Road wheel attaching

nuts torque specification ...........................110 – 140 Nm

10 Reinstall decorative wheel nut caps.

11 Carry out the Brake Pad Bedding-In Procedure, detailed in this Section.

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Rear Brake Pads

Remove

1 Using a G-clamp as shown, tighten unti l the caliper

piston bottom in its bore.

Figure 5A – 15

2 Using a suitable set spanner to hol d the lower guide

pin, use a suitable ring spanner remove the guide pin

bolt (1). Discard the removed bolt.

NOTE

• Old bolts must not be re-used as they are

vital safety components which have a micro-

encapsulated adhesive on the bolt threa d.

• While the disc rotor shown is solid, the

Coupe arrangement is t he same, except with

a vented rotor.

3 Swing the caliper assembly up from the anch or plate

and disc. Using a wire hook, support the caliper.

4 Remove the worn pads from the anchor plate.

5 Inspect the brake disc condition. Refer to

3.7 Rear Brake Disc.

6 Check the guide pins for free movement in the anchor

plate. If there is restriction of movement, replace the

guide pins and/or guide pi n boots. Refer to

3.5 Rear Brake Caliper.

7 Clean any dirt from both the piston face, which

contacts the inner pad, and the caliper head area

which contacts the outer pad.

Figure 5A – 16

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Reinstall

For noise damping effectiveness, it is critical that the brake

pad and shim assemblies are installed in the correct

locations. For example:

a The outer pad (1) (which is retained by the fingers of

the brake caliper housing), has a full shim.

b The inner pad (2) has a shim that has an asymmetrical

cut-out above the caliper piston and must be correctly

installed to the caliper by having the cut-out on the

lower half of the pad when installed in the caliper (in-

car position).

As illustrated, the brake pads shown, should onl y be fitted to

the left hand side, rear brake caliper.

1 Reinstall caliper housing over brake pads. Ensure

spring clip is located correctly in the top of the cali per

body.

2 Install a NEW guide pin, self locking bolt.

3 Use a suitable set spanner to prevent the guide pin

from rotating, then tighten the guide pin bolt to the

correct torque specification.

 Brake caliper guide pin

bolt torque specification........................................32 Nm

NOTE

Do not wedge anything between the guide pin

hex and the caliper as this could cause incorrect

alignment of the pin, restricting the free sliding o f

the caliper relative to the anchor plate. Figure 5A – 17

4 Fill master cylinder to correct level with fresh brake fluid of the correct spec ificatio n.

5 Depress brake pedal sev eral times to bring pad assemblies into position against disc.

6 Refill master cylinder if neces sary.

7 Reinstall wheels, aligning marks made prior to removal and lower vehicle to the ground.

8 Tighten road wheel attaching nuts to the specified torque, working in a star pattern (refer to

2.1 Service Warnings, Cautions and Notes, in this Section.

Road wheel attaching

nuts specification ......................................110 – 140 Nm

9 Reinstall decorative centre wheel cover.

10 Carry out the Brake Pad Bedding-In Proc edure, detailed in this Section.

Brake Pad Bedding-In Procedure

Whenever brake pads ar e replaced, they should be burnished, by the follo wing bedding-in procedure:

1 Perform a minimum of 10 moderate (0.3 to 0.4 g deceleration) brake applications from 70 km/h down to 40 km/h

every 500 metres.

NOTE

• A panic stop would be classified as being a

0.9 g deceleration braking effort, so a

moderate deceleration rate of 0.4 g would be

one that requir ed ap pro ximatel y half t he brak e

pedal effort needed for a panic stop.

• Do not perform this procedure at less than

500 metre intervals, as the excessive heat

build-up, may adversely affect the frictional

characteristics of the new brake pad material.

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2.8 Brake Pedal Assembly

LT Section No. – 04-600

Remove

Disable the SRS (Air Bag). Refer to

Section 12M Occupant Protection System.

1 If fitted, remove front suspension strut tower brace, refer to Section 1A1 Body.

2 Thoroughly cle an around the master cylinder, paying

particular attention to the reservoir cap and b r ake line

connections.

Brake fluid will damage the paint work if it

comes into contact with it. Should spillage

occur onto paint work, immediately wash the

brake fluid off with water.

3 Remove the master cylinder reservoir cap and set to

one side.

4 Using a hand vacuum pump (1), special tool J23738-A

or a commercially available hand vacuum pump or

syringe, siphon as much brake fluid from the master

cylinder reservoir (2) as possible.

NOTE

Hold the brake fluid level float down with the

suction tube, during this operation.

5 Reinstall the reservoir cap.

Figure 5A – 18

6 Disconnect the brake lines (5) from the master cylinder

(2) and allow any residual br ake fluid to drain from the

master cylinder into a container.

7 Plug the openings in both the master c ylinde r and the

pipes to prevent fluid loss and dirt ingress.

8 Remove the bolt (1) securing the master cylinder

bracket (4) to the end of the master cylinder (2).

NOTE

If the vehicle is fitted with the manual

transmission, support the clutch fluid reservoir

bracket, during bolt (1) removal. Use tie wire to

secure the reservoir and bracket in an upright

position, to one side.

9 Remove the nuts (3) securing the master cylinder

bracket (4) to the adjacent strut tower.

10 Remove the bracket (4) securing the master cylinder

to the adjacent strut tower. Figure 5A – 19

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11 As required, remove the following c ompo ne nts:

a Instrument panel lower trim panel assembly, refer to Section 1A3 Instrument Panel and Console.

b Driver side instrument panel lower trim plate assembly, refer to Section 1A3 Instrument Panel and Console.

c Instrument panel lower trim panel retainer, refer to Section 1A3 Instrument Panel and Console.

d Remove the Body Control Module (BCM) from its mounting bracket but le ave all electrical connectors

installed, refer to Section 12J Body Control Module.

12 Disconnect the wiring harness connectors from the

stop lamp switch (1) and the cruise cancel switch (2).

NOTE

Refer to Section 12E Cruise Control for further

information on the cruise control switch.

Figure 5A – 20

13 Disconnect the accelerator pedal wiring harness

connector (1) from the accelerator pedal sen s or (2).

Figure 5A – 21

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14 Remove the four nuts (1) securing the accelerator

pedal sensor bracket (2) to the brake pedal support

bracket and the dash panel.

Figure 5A – 22

15 Remove the remaining two nuts (1) securing the brake

booster to the brake pedal support bracket.

16 Remove the three bolts (2) securing the brake ped al

support bracket to the dash reinforcement.

17 From the engine compartment, pull the brake booster

forward, to disengage the four studs from the brake

pedal support bracket.

18 Lower the brake pedal assembly, rear end first and

removed from under the instrument panel.

Figure 5A – 23

19 Remove the push rod retaining clip (1), pus h rod (3)

and washers (2 and 4) from the brake pedal .

Figure 5A – 24

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Disassemble

1 Remove the nut (3) and washer (4) securing the brake

pedal shaft (5) to the brake pedal support (5).

2 Carefully remove the shaft and washer (6) from the

brake pedal support (2).

3 Withdraw the brake pedal (7) and return spring (8)

assembly.

4 Turn the cruise cancel switch (10), to the left (counter-

clockwise), then pull to remove from the brake pedal

support (2).

5 Turn the stop lamp switch (9), to the left (counter-

clockwise), then pull to remove from the brake pedal

support (2).

Reassemble

1 Lubricate all bearing surfaces (indicated by the symbol

) with an NLGI No. 2 lithium soap based EP grease

with molybdenum disulphide, such as Shell Retinax

HDX2 grease or BP Energrease LMS-EP 2 3 (or

equivalent).

2 Hold the brake pedal (7) and return spring (8) in

position and insert the brake ped al support shaft (5)

and washer (6) through the brake pedal support (2).

3 Reinstall the brake peda l shaft retaining washer (4)

and nut (3), then tighten to the correct torque

specification.

Brake pedal support shaft nut

torque specification...............................................55 Nm Figure 5A – 25

4 If removed, reinstall the cruise cancel switch (10):

a Insert the switch into the pedal bracket switch retainer, with the wiring harness connector at the 1 o'clock

position.

b Push the switch into the retainer and turn clockwise until the wiring harness connector is at the 3 o'clock

position. At this point a click should be felt, indicating that the switch is locked into place. No further

adjustment is required.

5 If removed, reinstall the stop lamp (9), following the same procedure as for the cruise cancel switch.

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Reinstall

1 Reinstall the brake pedal assembly into the vehicle and install the three bolts (2) securin g the brake pedal support

assembly to the steering column, refer to Figure 5A – 23. Do not tighten the bolts at this time

2 Push the brake booster rear ward to engage the four studs with the brake pedal support assembly.

3 Reinstall the push rod (3), washers (2 and 4) and retaining clip (1). Refer to Figure 5A – 24.

4 Reinstall the accelerator pedal assembly, refer to Figure 5A – 22.

5 Reinstall and tighten the four brake pedal assembly to brake booster nuts to the correct torque specific ation.

Brake pedal support to brake

booster nut torque specification............................25 Nm

6 Reinstall and tighten the two remaining accelerator pedal assembly to dash panel nuts to the specified torque.

Refer to Figure 5A – 22.

Accelerator pedal sensor bracket

attaching nut torque specification..........................25 Nm

7 Reinstall the wiring harness connectors to the stop lamp and the cruise cancel switches.

8 Reinstall the accelerator pedal sensor wiring harness connector, refer to Figure 5A – 21.

9 Tighten the three brake pedal support bracket to the dash reinforcement bolts to the correct torque specificatio n,

refer to '2' in Figure 5A – 23.

Brake pedal support bracket

bolt torque specification........................................25 Nm

10 Reinstall the master cylinder support bracket and tighten the nuts and bolt to the correct torque specification.

Master cylinder to bracket

bolt torque specification........................................10 Nm

Master cylinder bracket to strut tower

attaching nuts torque specification..........................8 Nm

11 Place a clean container under the brake master cylinder, unplu g the brake lines and master cylinder outlet ports

and reinstall the pipes to the master cylinder, refer to Figure 5A – 19.

12 Tighten the brake pipe flare nuts to the correct torque specification.

Brake pipe to master cylinder

flare nut torque specification.................................14 Nm

13 Bleed the brake system. Refer to 2.4 Brake System Bleed, in this Section.

14 Reinstall the instrument panel lower trim panel retainer, lower trim panel and driver side lower trim plate, refer to

Section 1A3 Instrument Panel and Co nsole.

Enable the SRS (Air Bag). Refer to

Section 12M Occupant Protection System.

15 Road test the vehicle to check for correct brake, stop lamp and cruise control operation.

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2.9 Park Brake Lever

LT Section No. – 04-675

Remove

1 Remove the right hand front seat. Refer to Section 1A7 Seat Assemblies .

2 Set the park brake in the fully released position.

3 Slip the park brake lever boot (1) to one side, then

remove the park brake front cable adjusting nut (2),

using a deep socket.

4 Whilst holding the park brake lever bo ot (1) to one

side, use a screwdriver (2) to prise the park brake

warning lamp switch harness r etain ing clip (3) from the

transmission tunnel.

Figure 5A – 26

Figure 5A – 27

5 Remove the floor console cover assembly. Refer to Section 1A3, Instrument Panel and Console.

6 Disconnect the park brake warning lamp switch harness connector (1) from the main vehicle wiring harness

connector (2).

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Figure 5A – 1

7 While holding the park brake lever boot (1) to one

side, remove the park brake lever retaining bolt (2),

two places.

8 Carefully lift the park brake lever assemb ly upwards to

free the cable (2).

9 Remove the lever assembly from the vehicle.

Figure 5A – 28

Reinstall

Reinstallation is the reverse of the removal procedure, noting the following:

1 Tighten the park brake lev er bolts to specified torque.

Park brake lever bolt

torque specification...............................................50 Nm

2 Reinstall the threaded end of the front park brake cable and then install the adjusting lock nut. Adjust the park

brake cable. Refer to 2.2 Park Brake Cable, Adjust, in this Section.

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2.10 Park Brake Warning Lamp Switch

LT Section No. – 04-675

Remove

1 Remove the park brake lever. Refer to 2.9 Park Brake Lever, Remove, in this Section.

2 Remove the park brake warning lam p switch retaining

screw (1), and remove the switch (2).

Figure 5A – 29

Inspect

1 While holding the park brake warning lamp switch (1),

depress and release the plunger (2), checking that the

plunger moves freely.

2 Using a multimeter, check that there is continuity

between the terminal (3) and t he switch body.

3 With the multimeter still connected, check that there is

no continuity when the s witch plunger is depressed.

4 If any of the above tests fail, replace the park brake

warning lamp switch.

Figure 5A – 30

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Reinstall

Reinstallation is the reverse to the removal proce dure, noting the following:

1. Tighten the park brake warning lamp switch retaining screw to the specified torque.

Park brake warning lamp switch

screw torque specification.......................................2 Nm

NOTE

For further information on the park brake

warning lamp operation, refer to Section 12C

Instrumentation.

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2.11 Front Park Brake Cable

LT Section No. – 04-675

Remove

1 Set park brake in the fully released p osition.

2 Remove driver’s seat. Refer to Section 1A7 Seat

Assemblies for the procedure.

3 Remove the park brake lever (1). Refer to

2.9 Park Brake Lever, in this Section.

4 Remove the centre console and lift the carpet to gain

access to the two front cable escutcheon screws (3).

Refer to Section 1A3 Instrument Panel and Console,

for details.

5 Remove the two screws (3).

6 Raise the vehicle and suppor t in a safe manner. Refer

to Section 0A General Information for the location of

the recommended lifting and support points. Figure 5A – 31

7 Pull each park brake inner rear cable (1) forward and

up (A), out of the equaliser bracket (2) to release.

8 Pull the outer cables (3) to the rear (B) to remove the

cable from the underbody retaining bracket (4).

9 Remove the front cable outer cable retaining bracket

bolt from the vehicle underbod y, refer to ‘4’ in

Figure 5A – 31.

NOTE

Depending on the engine/transmission fitted to

the vehicle, it may be necessary to first remove

the propeller shaft to enable access to this bolt.

Refer to Section 4C1 Rear Propeller Shaft and

Universal Joints for the proce dure. Figure 5A – 32

10 Manoeuvre the front cable assembly and equaliser bracket, through the aperture in the floo r pan, removing the

cable assembly from inside the vehicle.

Reinstall

Reinstallation is the reverse to the removal procedure, a pa r t from the following:

1 Manoeuvre the front cable and equ aliser bracket assembly, through the hole in the floor p an, ensuring that the

rubber seal is correctly positioned. Install the two self tapping screws ('3' in Figure 5A – 31) securing the plate to

the floor pan and tighten to the correct torque specification.

Front park brake cable plate retaining

screw torque specification....................................2.0 Nm

2 Reinstall the park brake lever and tighten bolts ('2' in Figure 5A – 31) to the specified torque.

Park brake lever bolt

torque specification...............................................50 Nm

3 Reinstall the park brake front cable adjusting nut a few threads to secure the cable.

4 Reinstall the outer front cable retaining bracket bolt to the vehicle underbody ('4' in Figure 5A – 31) , tightening to

the correct torque specification.

Outer front cable bracket

bolt torque specification........................................25 Nm

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5 As required, reinstall the propeller shaft. Refer to Section 4C1 Re ar Propeller Shaft and Universal Joints for the

procedure and the specified torque specifications.

6 Reinstall the driver’s seat and centre console. Refer to Section 1A7 Seat Assemblies and

Section 1A3 Instrument Panel and Co nsole, for the necessary procedures.

7 Reinstall the two rear cables to the eq ualiser bracket.

8 Adjust the park brake. Refer to 2.2 Park Brake Cable, Adjust in this Section.

9 Lower the vehicle to the ground

10 Check for correct park brake operation.

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2.12 Rear Park Brake Cable/s

LT Section No. – 04-675

Remove

1 Release park brake.

2 Using a deep socket, loosen the front cabl e adjusting

nut (arrow) until the nut is almost removed.

3 Using a floor jack under centre of differential carrier,

jack up and support rear of vehicle on safety stands

under rear trailing arms.

Figure 5A – 33

4 To provide sufficient access, it may be necessary to

remove the propeller shaft from the vehicle. Refer to

Section 4C1 Rear Propeller Shaft and Univer sal Joints

for the necessary procedures.

5. As required, unclip the cable/s (2) from the underbody

clip/s (1).

Figure 5A – 34

1 Remove the front of the rear inner cable/s (1), by first

wrapping rag around the inner cable to protect it from

damage, then use pliers to pull the ba ll nipple forward

and up (A), to free from the equaliser bracket (2).

2 Pull the outer cable/s (3) rearward (B) to release from

the vehicle underbody bracket (4).

Figure 5A – 35

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3 Disconnect the rear clevis from the rear park brake

actuating lever by gripping with pliers and pivoting the

cable rearwards.

Figure 5A – 36

Reinstall

Reinstallation of the rear park brake cable/s is the reverse of removal procedure, except for the following points:

1 Reinstall the cable throu gh the trailing arm retainer, then fit the cable cl evis to the park brake actuating lever.

2 Pull the outer cable/s forward to reinstall into the vehicle underbo dy bracket.

3 Wrap rag around the inner cable to protect it from damage, then use pli ers to pull the ball end on the inner cable

forward to engage into the equaliser bracket.

4 If removed, reinstall the propeller shaft. Refer to Section 4C1 Rear Propeller Shaft and Universal Joints for all

details.

5 Adjust park brake cable, refer to 2.2 Park Brake Cable, Adjust, in this Section.

Service and Park Braking Systems Page 5A-36

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2.13 Front Caliper Brake Hose

LT Section No. – 04-750

Remove

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove the wheel covers or decorative wheel nut caps, then mark the relationship of the road wheel to one of the

wheel studs.

3 Loosen, then remove the road wheel attaching nuts, working in a 'star' pattern. Refer to 2.1 Service Warnin gs,

Cautions and Notes in this Section, for detailed information. Remove the road wheel.

4 Thoroughly cle an connections at each end of brake hose (1), refer to Figure 5A – 37.

5 Disconnect brake pipe (2) from hose (1), then plug pipe to reduce fluid loss.

6 Remove the screw (3) securing the hose bracket to the inne r skirt panel.

7 Remove the brake hose retaining clip at the suspension tower bracket by first, prising the end at the brake hose

end free, using a screwdriver or similar. Remove the clip from the strut bracket, then discard.

8 Rotate the brake hose until the flats on the b r ake hose grommet are aligned with the slot in the strut bracket, then

remove the hose and grommet.

NOTE

View 'A' shows the right front brake hose, while

view 'B' shows the left front brake hose.

Figure 5A – 37

9 Referring to Figure 5A – 38, remove the banjo bolt (2), sealing washers (3), then remove the brake hose (1) from

the caliper. Discard the removed copper washers, as they must be replaced on reassembly.

Techline

Service and Park Braking Systems Page 5A-37

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Reinstall

1 Ensure brake hose and caliper mating surfaces are

clean and free from burrs.

2 Reinstall brake hose (1) to caliper, using NEW copper

sealing washers (3), then tighten the b anjo bolt (2) to

specified torque.

Brake hose to caliper banjo

bolt torque specification........................................35 Nm

Figure 5A – 38

3 Reinstall hose and gr ommet into suspension strut bracket, refer to ‘4’ in Figure 5A – 37. Secure by turning the

grommet through 90°.

4 Install a NEW brake hose retaining clip, as follows:

a Slide one end of the retaining clip (1) over the

brake hose retaining bracket (2) at point ‘X’,

checking that the strut bracket is aligned with the

slot in the clip.

Figure 5A – 39

b While holding the installed end ‘X’ in place,

rotate the clip around the brak e hose retaining

bracket until the clip ‘clicks’ into position, at point

‘Y’.

c Squeeze the clip firmly with the thumb and

forefinger of one hand as indic ated, to ensure

that the clip ends are fully engage d.

Figure 5A – 40

5 Reinstall the scre w (3) to retain the hose bra cket to the inner skirt panel.

6 Remove plug from brake pipe (2) and rec on nect to hose (1).

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7 Tighten the flare nut to the correct torque specification.

Brake pipe to brake hose

flare nut torque specification.................................15 Nm

8 Check that the brake hose is not twisted.

9 Bleed brake/s, refer 2.4 Brake System Bleed, in this Section.

10 Reinstall road wheel, aligning marks made on removal and lower vehicle.

11 Tighten road wheel attaching nuts to the correct torque specification, working in a star pattern, refer to

2.1 Service Warnings, Cautions and Notes, in this Section.

Road wheel attaching

nut torque specification.............................110 – 140 Nm

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2.14 Rear Caliper Brake Hose

LT Section No. – 04-750

Remove

1 Raise rear of the vehicle and support in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove the decorative wheel nut caps, then mark the relationship of the road wheel to one of the wheel studs.

3 Loosen, then remove the road wheel attaching nuts, working in a 'star' pattern. Refer 2.1 Service Warnings,

Cautions and Notes in this Section, for detailed information. Remove the road wheel.

4 Thoroughly cle an connections at each end of brake

hose (1).

5 While holding the hose (1) with a back-up spanner,

loosen then disconnect brake pipe (2) from brake hose

(1). Plug the pipe open end.

6 Remove retainer clip (3) from hose and withdraw hose

from bracket (4).

7 Remove the banjo bolt (5) and two copper washers

(6). Unbolt and remove brake hose from caliper.

Figure 5A – 41

Reinstall

1 Ensure brake hose and caliper mating surfaces are clean and free of burrs.

2 Reconnect brake hose to caliper, ensuring that the locating peg al igns with the dimple in the caliper. Use NEW

copper sealing washers, then tighten the banjo bolt to specified torque.

Brake hose to caliper banjo

bolt torque specification........................................35 Nm

3 Fit hose correctly into mountin g plate bracket and reinstall retainer. Check that hose is not twisted.

4 Remove plug from brake pipe and rec on nect to hose. While using a back-up spanner on the brake hose to prevent

twisting, tighten pipe to specified torque.

Brake pipe to brake hose flare

nut torque specification.........................................15 Nm

5 Bleed brake/s, refer to 2.4 Brake System Bleed, in this Section.

6 Reinstall road wheel, aligning marks made on removal and lower vehicle.

7 Tighten road wheel attaching nuts to the specified torque, tightening in a star pattern, refer to

2.1 Service Warnings, Cautions and Notes, in this Section.

Road wheel attaching bolt

torque specification...................................110 – 140 Nm

8 Road test the vehicle to ensure correct brake operation.

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2.15 Rear Brake Hoses

LT Section No. – 04-750

Remove

1 Raise rear of the vehicle and support in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Thoroughly cle an connections at each end of the rear brake hose to be removed.

Figure 5A – 42

Legend

View A LH Shown – RH opposite

View B With ABS/TC – LH shown, RH opposite

View C RH shown, LH opposite

Align Flats on Bracket and Hose

1 Rear Brake Pipe

2 Rear Brake Hose, Caliper to Rear Brake Pipe

3 Rear Brake Hose

4 Retaining Clip

5 Brake Hose Connection Pipe

3 Disconnect brake pipe (5) from brake hose (3) at trailing arm brackets (View B). Plug open end of brake pipe/s to

reduce fluid loss and to prev ent foreign matter entry.

4 Disconnect rear brake pipe (1) connection from brake hose (3) (Vie w A), while holding the hose with a back-up

spanner. Plug all pipe ends to prevent fluid loss and foreign material entry.

5 Remove retaining clips (4) from the end of each hose end and withdraw hose/s from brackets.

NOTE

Refer to Operation 2.14 Rear Caliper Br ake Hose

for procedure to remove the rear caliper hose (2).

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Reinstall

1 Ensure brake hose ends and pipe mating surfaces are clean and free of burrs.

2 Fit hose (3) into mounting plat e brackets and reinstall retaining clips (4). Check that the hose (3) is n ot twisted.

3 Remove plugs from brake pipes (1 and 5), then reconnect to hose ends. Tighten all pipe nuts to specified torque.

Brake pipe flare nut to brake

hose torque specification ......................................15 Nm

4 Bleed brake/s, see 2.4 Brake System Bleed, in this Section.

5 Lower vehicle to the ground and road test to check for corre ct brake operation.

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2.16 Brake Booster Hose & Valve Assembly –

V6 Engine

Replace

1 Unclip and remove the right side engine dress cover.

Wear eye protection to prevent potential

injury.

2 Using suitable pliers, com press the spring hose clamp

(1) at each end of the brake booster vacuum hose (2)

and slide both clamps back along the hose.

3 While supporting the vacuum check valve at the

booster end, twist the hose to break the seal, then

remove by twisting back and forth while maintaining a

constant pulling force on the hose.

Figure 5A – 43

4 Repeat step 3 for the intake manifold fitting at the rear

of the engine.

5 Reinstallation is the reverse of the removal process,

except that each hose clip (1) must be reinstalled over

the hose (2) and behind the nipple at each end to

prevent hose premature disengagement.

6 Reinstall the right side, engine dress cover.

Figure 5A – 44

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2.17 Brake Booster Hose & Valve Assembly –

GEN III V8 Engine

Replace

1 Remove the suspension tower brace. Refer to Section 1A1 Body.

Wear eye protection to prevent potential

injury.

2 Using suitable pliers, com press the spring hose clamp at ea ch end of the brake booster vacuum hose and slide

both clamps back along the hose.

3 While supporting the vacuum check valve at the booster end, twist the hose to break the seal, then remove b y

twisting back and forth while maintaining a constant pulling force on the hose.

4 Repeat step 3 for the intake manifold fitting at the rear of the engine, supporting the fitting during the removal

process.

5 Reinstallation is the reverse of the removal process, except that each hose clip must be reinstalled ov er the hose

and behind the nipp le at each end to prevent premature hos e disengagement. Also ensure that the blue alignment

dot on the hose is facing upward.

Figure 5A – 45

Legend

1 GEN III V8 brake booster vacuum hose.

2 Retaining clip, brake booster end.

3 Retaining clip, engine manifold end.

Blue spot to be on top.

Ensure hose ends are clamped behind the ridge on the nipple.

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2.18 Brake Fluid Level Switch

Test

1 Carefully wipe around the reservoir cap, then remove the c ap,

2 Using a small bladed screwdriver, lift the connector

security clip locking the br ake fluid level switch

harness connector, then remove the connector from

the switch.

Figure 5A – 46

3 Check that the brake fluid level is at the 'M AX' mark.

4 Using a multimeter set to Ohms, check that the

resistance is high (approximately 10 kΩ).

5 While holding the multimeter leads on the switch

terminals, use a thin bladed sc rewdriver to gently push

the brake fluid float to the bottom of the reservoir and

hold in this position.

6 Check that, when the float is fully depressed, the

resistance across the switch terminals drops to a

minimal resistance (approximately 3 Ω).

7 Should either test not meet the above criteria, then the

switch is faulty and must be replaced.

NOTE

As the switch is not serviced separately to the

reservoir, then this too, must be replaced. Refer

to 3.2 Brake Master Cylinder Reservoir,

Replace, in this Section. Figure 5A – 47

Replace

1 Replace the brake fluid reservoir. Refer to 3.2 Brake Master Cylinder Reservoir, Replace, in this Section, for the

procedure.

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3 Major Service Operations

3.1 Master Cylinder

LT Section No. – 04-725

Remove

1 If a front suspension strut brace is fitted to the vehicle, removing it will provide easier access to the master cylinder

fasteners. Refer to Section 1A1 Body.

2 Apply the brake pedal at least five times to exhaust all stored vacuum from the braking system.

3 Thoroughly clean the master cylinder, espec ially around the brake line connections and reservoir cap.

4 Remove the master cylinder reservoir cap.

Brake fluid will cause damage to the paint

work. If contact does occur, immediately

wash the brake flui d o ff with water.

5 Using a hand vacuum pump (1) such as Tool J23738-

A or a commercially available hand vacuum pump or

syringe, siphon as much brake fluid from the master

cylinder reservoir (2) as possible.

6 Using a small bladed screwdriver, lift the connector

security clip locking the br ake fluid level switch

harness connector, then remove the connector from

the switch.

Figure 5A – 48

7 Disconnect the brake pipes (5) from the master

cylinder (2) and allow any residual brake fluid to drain

from the master cylinder into a container.

8 Plug all openings in both the master cylinder and the

pipes to prevent fluid loss and dirt ingress.

9 Remove the two nuts (3) securing the master c ylinder

bracket (4) to the strut tower.

10 Remove the bolt (1) securing the bracket (4) to the

end of the brake master cylinder (2).

NOTE

For vehicles with manual transmission, removal

of the clutch master cylinder fluid reservoir and

bracket will also occur. After removal of the bolt

(1), secure the clutch reservoir and bracket with

tie wire, to one side and in an upri ght position.

Figure 5A – 49

11 Remove the nuts (6) securing the master cylinder to the brake booster, then remove the master cylinder and

sealing O-ring from the booster assembl y and the vehicle.

NOTE

DO NOT disturb the brake booster push ro d, and

DO NOT depress the brak e peda l with the m aster

cylinder removed, or internal damage to the

booster may occur.

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Reinstall

The reinstallation proced ure for the master cylinder is the reverse of the removal procedure, noting the following:

1 Install a new O-ring (4) to the master cylinder body (3)

on the mounting flange end.

2 Reinstall the master cylinder assembly to the brake

booster, taking care not to disturb the brak e booster

push rod.

Figure 5A – 50

3 Reinstall the master cylinder mounting nuts, then

tighten the nuts to the correct torque specification.

Master cylinder attaching

nut torque specification.........................................10 Nm

4 Reinstall the master cylinder s upport bracket (4) (and

clutch fluid reservoir, as required).

5 Reinstall and tighten the nuts (3) and bolt (1) to the

correct torque specification.

Master cylinder to bracket

bolt torque specification........................................10 Nm

Master cylinder bracket to strut tower

attaching nuts torque specification..........................8 Nm

6 Place a clean container under the master cylinder,

unplug the brake lines and master cylinder outlet

ports, then reinstall the pipes to the master cylinder. Figure 4A1 – 51

7 Tighten the brake pipe flare nuts to the correct torque specif ication.

Brake pipe to master cylinder

flare nut torque specification.................................14 Nm

8 Reconnect the electrical connector to the brake fluid level switch. Check that the locking spring clip is correctly

installed.

9 Refill the master cylinder reservoir. Refer to 2.3 Brake Fluid Level Check, in this Section.

10 Bleed the brakes. Refer to 2.4 Brake System Bleed, in this Section.

11 Road test the vehicle to ensure correct brake operation.

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3.2 Brake Master Cylinder Reservoir

Replace

1 Remove the brake master cylinder from the v ehicle. Refer to 3.1 Brake Master Cylinder, Remove, in this Section.

2 Remove the two screws (6) securing the reservoir (3)

to the master cylinder body (5).

3 Grasp the master cylinder bod y (5) with one hand,

then pull on the reservoir (3) with the other, to remove.

4 Lubricate new seals (4) with brake fluid, then install to

the master cylinder body (5).

5 Install the reservoir (3) to the master cylinder body (5).

6 Reinstall the two securing screws (6) and tighten to

the correct torque specification.

Brake fluid reservoir attaching

screw torque specification....................................2.5 Nm

7 Reinstall the brake master cylinder. Refer to

3.1 Brake Master Cylinder, Reinstall, in this Section.

8 Bleed the braking system, then road test to ensure

correct brake operation. Refer to 2.4 Brake System

Bleed, in this Section. Figure 5A – 52

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3.3 Brake Booster

LT Section No. – 04-725

NOTE

The brake booster is not a serviceable item and if

found to be faulty, must be replaced as a unit.

Remove

With the master cylinder removed, do not

disturb the brake booster push rod nor

depress the brake pedal, as the reaction disc

in the booster may become dislodged.

1 Where applicable, remov e the following components:

a Front suspension strut tower brace, refer to Section 1A1 Bod y.

b Instrument panel lower trim panel assembly, refer to Section 1A3 Instrument Panel and Console.

c Driver side instrument panel lower trim plate assembly, refer to Section 1A3 Instrument Panel and Console.

d Instrument panel lower trim panel retainer, refer to Section 1A3 Instrument Panel an d Console.

e Remove the Body Control Module (BCM) from its mounting bracket but le ave all electrical connectors

installed, refer to Section 12J Body Control Module.

2 Remove master cylinder, refer to 3.1 Master Cylinder in this Section.

3 Remove vacuum hose from brake booster vacuum check valve. Refer to 2.16 Brake Booster Hose – V6 Engine or

2.17 Brake Booster Hose – GEN III V8 Engine, in this Section.

4 For vehicles fitted with the V6 engine, remove the t wo heater pipes from the rear of the engi ne. Refer to

Section 6B1 Engine Co oling – V6, for details.

5 Remove push rod retaining cli p (1), washer (2), push

rod (3) and washer (4) from brake pedal.

Figure 5A – 53

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6 Remove the four nuts (1) securing the accelerator

pedal sensor bracket (2) to the brake pedal support

bracket and the dash panel.

7 Remove the accelerator pedal sensor and bracket

assembly.

Figure 5A – 54

8 Remove the remaining two nuts (1) securing the brake

booster to the brake pedal support bracket.

9 From the engine compartment, pull the brake booster

forward, disengaging the four studs from the brake

pedal bracket and remove the brake booster from

engine compartment.

Figure 5A – 55

Reinstall

Installation is the reverse of the removal procedure, except for the following:

1 Lubricate brake pedal and push rod component bearing surfaces with an NLGI No. 2 lithium soap based EP grease

with molybdenum disulphide, such as Shell Retinax HDX2 greas e or BP Energrease LMS-EP 23 (or equivalent).

Refer to Figure 5A – 25 and the symbol ' ' for the locations.

2 Reinstall the brake booster retaining nuts and tighten to the correct torque specific ation.

Brake booster retaining

nut torque specification.........................................25 Nm

3 Reinstall master c ylinder. Refer to 3.1 Master Cylinder, in this Section.

4 Ensure brake booster vacuum hose is routed correctly and check that the retaining hose clips are installed

correctly, refer to 2.16 Brake Booster Hose & Valve Assembly – V6 Engine or 2.17 Brake Booster Hose & Valve

Assembly – GEN III V8 Engine, in this Section.

5 Road test vehicle and check for correct brake operation.

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3.4 Front Brake Caliper

ATTENTION

The following fasteners MUST be replaced when performing these operations:

 Front brake caliper anchor plate to steering knuckle attaching bolts.

 Brake caliper gu i de pin bolts

Remove

1 Raise the front of the vehicle and place on safety stands. Refer to Section 0A General Information for the location

of jacking and support points.

2 Remove the decorative wheel nut caps, then mark the relationship of the road wheel to one of the wheel studs.

3 Loosen, then remove the road wheel attaching nuts, working in a 'star' pattern. Refer 2.1 Service Warnings,

Cautions and Notes in this Section, for detailed information. Remove the road wheel.

4 Place a drain tray beneath the caliper assembly.

5 Loosen and remove the brake hose to caliper banjo

bolt (1). Separate the bolt from the hose (3) and

discard the two sealing washers (2).

6 Plug the open end of the brake hose (3) to prevent

fluid loss and foreign material entry.

7 Remove the two anchor plate retaining bolts (4) and lift

the caliper assembly out over the disc.

Figure 5A – 56

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Disassemble

1 Refer to Figures 5A – 57; use an open end spanner to hold the guide pin (4) flat section and remove and discard

the guide pin bolts (3).

2 Separate the caliper ho using (1) from the anchor plate (6).

3 Remove the brake pads (7 and 8) and clips (12).

4 Remove the guide pins (4) and boots (5) from the anchor plate (6). Separate boots from pins.

Figure 5A – 57

Legend

1 Caliper Housing

2 Bleeder Screw

3 Guide Pin Bolt (2 places)

4 Guide Pin (2 places)

5 Guide Pin Boot

6 Caliper Anchor Plate

7 Outer Brake Pad

8 Inner Brake Pad

9 Piston Boot (2 places)

10 Piston (2 places)

11 Piston Sealing Ring (2 places)

12 Clip ( 2 places)

Only apply light air pressure initially and

progressively increase until the piston is

forced out of the bore. This is necessary to

avoid physical injury, as the piston may eject

with considerab le force.

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5 Pack a clean piece of cloth between the caliper

piston/s and opposite legs on the housing and apply

air pressure at the brake hose inlet port to eject a

piston.

Figure 5A – 58

6 As only one piston in the front caliper will be removed by this method, removal of the second will need to be done

by using internal expandin g circlip pliers, to grasp the inner piston wall. Then, while rotating the piston back and

forth, apply a pulling force to remove the piston from its bore.

7 Remove the piston boots (9) from the piston/s (10).

8 Remove the piston sealing ring (11) from the bore, taking c are not to damage the bore or seal locatin g groove.

9 Remove the brake caliper ble eder (2) and dust cap (13).

Clean and Inspect

1 Clean all metal parts thoroughly with methylated spirits. Clean rub ber parts with brake fluid only. Use clean, dry

compressed air to dry parts.

2 Examine the bore and piston carefully for signs of damage, abrasion, scuffing or corrosion . Renew the piston if any

of these factors exist or if there is any doubt regarding its condition. If the bore is unserviceable, the cali per

assembly must be replaced.

3 Inspect the guide pins for corrosion. Replace the pins if corroded.

4 Blow through the brake caliper bleeder port with compressed air.

Reassemble

1 Lubricate the cylinder bore 1) and piston (2) with the

recommended brake fluid

2 Fit a new piston sealing ring into the inner groove of

the cylinder bore. Ensure that the seal is not twisted

and is fully seated in its groove.

3 Install the piston boot (3) over the end of the piston

(2).

Figure 5A – 59

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4 Position each piston (1) into the caliper housing (2),

seating the boot (3) into a groove in the caliper bore

(4). Ensure the boot flange is squarely and firmly

seated in the groove.

5 Push the piston (2) squarel y into the bore by hand until

fully seated. Ensure the piston boot (1) is fully seated

in the piston (2) and caliper bore grooves.

Figure 5A – 60

To avoid uneven pad wear and/or noisy brake

operation, the assembly of the guide pins to

the caliper housing is critical and the

following MUST be followed:

6 Lubricate the guide pins (1) with silicone grease, such

as Dow Corning No. 44 or equivalent.

7 Fully install guide pins (1) into the anchor plate (5),

without the two boots (2).

Do not use the original bolts.

8 Reinstall the caliper housing (4) to the anchor plate (5)

and install NEW guide pin bolts (3). Figure 5A – 61

9 Use an open end spanner to hold the guide pin flat section, then tighten the new guide pin bolts (3) to the correct

torque.

() Brake caliper guide pin

bolt torque specification........................................32 Nm

Check that the caliper housing and guide pins

slide in and out easily from the anchor plate.

If any binding is evident, then steps 6 to 9

must be repeated.

10 Disengage the caliper housing from the anchor plate and install new guide pin boots to the guide pins.

11 Reassemble the caliper housi ng and anchor plate together. Squeeze each boot to remove excess air, then ensure

that each guide pin boot is correctly located in the guide p in and anchor plate grooves.

12 Reinstall the brake caliper b leeder.

13 Reinstall the brake pads, refer to 2.7 Brake Pads, Replace, in this Section.

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Reinstall

1 Ensure the anchor plate mounting surfaces are clean.

2 Press the inner brake pad by hand to ensure the piston is bottomed in the bore.

3 Referring to Figure 5A – 62 position the caliper assembly over the disc. Insert the NEW anchor plate retaining bolts

(4) and tighten to the correct torque specificat ion.

 Front brake caliper anchor

plate bolt torque specification.......................85 Nm, then

turn through 45°

4 Reconnect the brake hose (3) usin g NEW copper

sealing washers (2), then tighten the b anjo bolt (1) to

the correct torque specification.

Brake hose to caliper banjo

bolt torque specification........................................35 Nm

Figure 5A – 62

5 Bleed the brake/s. Refer to 2.4 Brake System Bleed, in this Section.

6 Depress the brake pedal several times to bring pads into position ag ainst the disc rotor.

7 Top up the master cylinder if necessary.

8 Reinstall road wheel in th e original position and secure with the wheel nuts but do not fully tighten.

9 Lower the vehicle to the ground an d tighten the wheel nuts to the specified torque, working in a star pattern, refer to

2.1 Service Warnings, Cautions and Notes, in this Section.

Road wheel attaching nut

torque specification...................................110 – 140 Nm

10 Install the wheel covers or decorative wheel nut caps.

11 Road test the vehicle to check for correct brake operation.

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3.5 Rear Brake Caliper

ATTENTION

The following fasteners MUST be replaced when performing these operations:

 Brake caliper gu i de pin bolts

Remove

1 Raise the rear of the vehicle and pl ace on safety stands. Refer to Section 0A General Information for the location of

jacking and support points.

2 Remove the wheel covers or decorative wheel nut caps, then mark the relationship of the road wheel to one of the

wheel studs.

3 Loosen, then remove the road wheel attachi ng nuts, working in a 'star' pattern. Refer 2.1 Service Warnings,

Cautions and Notes in this Section, for detailed information. Remove the road wheel.

4 Place a drain tray beneath the caliper assembly.

5 Loosen and remove the brake hose to caliper banjo

bolt (1). Separate the bolt from the hose and discard

the two sealing washers (2).

6 Plug the open end of the brake hose (3) to prevent

foreign material entry.

7 Remove the two anchor plate retaining bolts (4) and lift

the caliper assembly out over the disc.

Figure 5A – 63

Disassemble

1 Use an open end spanner to hold the guide pin flat section and remove and discard the guide pin bolts (1).

2 Separate the caliper ho using (2) from the anchor plate (7).

3 Remove the brake pads (8 and 9), together with the anti rattle spring clips.

4 Withdraw the guide pins (5) and boots (6) from the anchor plate (7). Separate boots from pins.

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Figure 5A-64

Legend

1 Guide Pin Bolt (2 places)

2 Caliper Housing

3 Brake Caliper Bleeder

4 Brake Caliper Bleeder Dust Cap

5 Guide Pin (2 places)

6 Guide Pin Boot (2 places)

7 Anchor Plate

8 Outer Brake Pad

9 Inner Brake Pad

10 Piston Boot

11 Piston

12 Piston Sealing Ring

Only apply light air pressure initially and

progressively increase until the piston is

forced out of the bore. This is necessary to

avoid physical injury, as the piston may eject

with considerab le force.

5 Pack a clean piece of cloth between the caliper

piston/s and opposite legs on the housing and apply

air pressure at the brake hose inlet port to eject the

piston.

6 Remove the piston boots (10) from the piston (11).

7 Remove the piston sealing rin g (12) from the bore,

taking care not to damage the bore or seal locating

groove.

8 Remove the brake caliper ble eder (3) and dust

cap (4).

Figure 5A – 65

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Clean and Inspect

1 Clean all metal parts thoroughly with methylated spirits. Clean rub ber parts with brake fluid only. Use clean, dry

compressed air to dry parts.

2 Examine the bore and piston carefully for signs of damage, abrasion, scuffing or corrosion . Renew the piston if any

of these conditions exist or if there is any doubt regarding its condition. If the bore is unserviceable, the caliper

assembly must be replaced.

3 Inspect the guide pins for corrosion. Replace pins if corroded.

4 Blow through the brake caliper bleeder port with compressed air.

Reassemble

1 Lubricate the cylinder bore (1) and piston (2) with the

recommended brake fluid

2 Fit a new piston sealing ring into the inner groove of

the cylinder bore. Ensure that the O-ring is not twisted

and is fully seated in its groove.

3 Install the piston boot (3) over the end of the piston.

Figure 5A – 66

4 Position the piston (1) into the caliper housing (2),

seating the boot (3) into a groove in the calip er bore

(4). Ensure the boot flange is squarely and firmly

seated in the groove.

5 Push the piston squarely into the bore by hand until

fully seated. Ensure the piston boot is fully seated in

the piston and caliper bor e grooves.

Figure 5A – 67

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To avoid uneven pad wear and/or noisy

brake operation, the assembly of the guide

pins to the caliper housing is critical and the

following MUST be followed:

6 Lubricate the guide pins (1) with silicone grease, such

as Dow Corning No. 44 or equivalent.

7 Fully install the guide pins into the anchor plate (2),

without the two boots (3).

Do not use the original bolts.

8 Reinstall the caliper housing (4) to the anchor plate

and install NEW guide pin bolts (5).

Figure 5A – 68

9 Use an open end spanner to hold the guide pin flat

section, then tighten the guide pin bolts (1) to the

correct torque specification.

 Brake caliper guide pin bolt

torque specification...............................................32 Nm

Check that the caliper housing and guide

pins slide in and out easily from the anchor

plate. If any binding is evident, then steps 6

to 9 must be repeated.

10 Reassemble the caliper housing and anchor plate

together. Squeeze each boot to remove e xc ess air,

then ensure that each guide pin boot is correctly

located in the guide pin and anchor plate grooves.

11 Reinstall the brake caliper b leeder.

12 Reinstall the brake pads, refer to 2.7 Brake Pads,

Replace.

Figure 5A – 69

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Reinstall

1 Ensure the anchor plate mounting surfaces (1) are

clean.

2 Press the inner brake pad inwards by hand to ensure

the piston is bottomed in the bore.

3 Position the caliper assembly (2) over the disc rotor.

4 Insert the two anchor plate retaining bolts (3), then

tighten to the correct torque specification.

Rear brake caliper anc hor

plate bolt torque specification................................85 Nm

5 Reconnect the brake hose (4) usin g NEW copper

sealing washers (5), then tighten the banjo bolt to the

specified torque.

Brake hose to caliper banjo

bolt torque specification........................................35 Nm

Figure 5A – 70

6 Bleed the brake/s. Refer to 2.4 Brake System Bleed, in this Section.

7 Top up the master cylinder if necessary.

8 Depress the brake pedal several times to bring pads into position against the disc.

9 Reinstall road wheel in th e original position and secure with the wheel nuts but do not fully tighten.

10 Lower the vehicle to the ground an d tighten the wheel nuts to the specified torque, working in a star pattern, refer to

2.1 Service Warnings, Cautions and Notes, in this Section.

Road wheel attaching nut

torque specification...................................110 – 140 Nm

11 Reinstall the decorative centre wheel cover.

12 Road test the vehicle to check for correct brake operation.

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3.6 Front Brake Disc

LT Section No. – 04-805

Remove

1 Raise the vehicle and suppor t in a safe manner. Refer to Section 0A General Information for the location of

recommended lifting and support points.

2 Remove the wheel covers or decorative wheel nut caps, then mark the relationship of the road wheel to one of the

wheel studs.

3 Loosen, then remove the road wheel attachi ng nuts, working in a 'star' pattern. Refer 2.1 Service Warnings,

Cautions and Notes in this Section, for detailed information. Remove the road wheel.

The brake disc to hub relationship is

carefully matched during production

(indexed), to minimise the effect of a

tolerance stack-up, that could result in disc

runout and subsequent brake shudder.

Therefore, before removal of the front brake

disc/s, check to see whether a paint daub

mark (1) is still visible on the brake disc hub

surface, adjacent to one of the wheel studs

and in alignment with the two marks (2) on

the end of the hub, as shown.

If the paint marks are no longer visible, then

carefully mark the relationship of the brake

disc to the hub for reinstallation, using a felt

tipped pen or similar. If this precaution is not

taken, then a disc runout condition could be

induced that will cause brake shudder.

Figure 5A – 71

NOTE

If the brake disc is being r emoved to rectify brake

shudder, if the brake disc is to be machined or

replaced, or if brake disc to hub matching is not

evident, then the brake disc to the hub must be

indexed. Refer to 3.6 Front Brake Disc, in this

Section.

4 Remove the brake caliper assembly, refer to 3.4 Front Brake Caliper in this Section.

NOTE

It is not necessary to disconnect the brake hose

from caliper. However, the caliper MUST be

supported with a wire hook to avoid strain on the

brake hose.

5 If the brake disc rotor has rusted and adhered to the wheel hub, first spray with a commercially availab le rust

penetrating fluid, then jar the brake disc loose by carefully tapping the disc in the centre between the wheel studs,

with a soft faced hammer (or similar). Do not damage the wheel stud threa ds during this process.

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Inspect

1 If the brake disc surface is rusted or lightly scored, resurface disc. Scores less than 0.4 mm deep will not affect

brake performance.

2 If scoring is deep or if brake disc parameters are out of specification, the disc must be machined.

NOTE

Machine or resurface BOTH sides of disc. D o not

machine or resurface one side onl y.

NOTE

After machining, the brake disc should be

ground to achieve a non-circumferential finish of

0.4 to 2.0 microns.

Figure 5A – 72

NOTE

After machining, the chamfer on the brake disc

outer diameter must be 45 deg x 1 mm

maximum (dimension A) with a pad (1) to

chamfer clearance of 1.3 mm minimum to 2.5

mm maximum (dimension B). This is to prevent

thermal stress cracking at the top of the disc (2).

Figure 5A – 73

The number cast into the hub (1) is the

minimum safe thickness. At this thickness,

the disc MUST be replaced .

Replace disc if specifications cannot be achieved above the

minimum disc thickness.

Minimum Brake Disc Thickness (replacement required)

All WL Series Models........................................25.0 mm

Figure 5A – 74

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3 Inspect disc as follows:

a Using a piece of chalk, mark the brake disc

every 30 deg (1).

b Using a dial indicator (2), check that lateral r un-

out of each braking surface does not exceed

0.04 mm Total Indicated Runout (TIR) and that

the rate of change does not exceed 0.03 mm in

30 degrees.

Maximum lateral runout (TIR) ...........................0.04 mm

Maximum lateral runout in 30°..........................0.03 mm

NOTE

This specification is the lateral run-out of a front

brake disc that has been removed from the

vehicle (do not confuse this with brake disc to

hub assembled lateral run-out.

Figure 5A – 75

4 Check that both surfaces of the brake disc (A & B) are

flat within 0.05 mm TIR.

Figure 5A – 76

5 Check that disc surfaces are parallel with each other

to within 0.08 mm, when checked radially.

NOTE

Taper variation must not exceed 0.08 mm.

Figure 5A – 77

6 Check that total circumferential thickness vari ation,

(also referred to as Disc Thickness Variation) at any

radius, does not exceed 0.005 mm in 360 degrees as

the brake disc is rotated.

NOTE

To measure the thickness variation, measure

both sides of the brake disc for runout and add

the two measurements together.

Example:

Total runout on one side = + 0.020 mm

Total runout on other side = – 0.015 mm

Therefore + 0.020 + – 0.015 = + 0.005 mm Figure 5A – 78

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Front Brake Disc and Hub Indexing Procedure

NOTE

Brake disc and hub indexing is required so the

minimum installed brake disc runout is achieved.

Brake disc and hub ind exing involv es aligning the

point of maximum runout on the hub with the

point of least runout on the brake disc.

NOTE

This procedure is to be used when reinstalling

brake discs that have been removed for

machining off-car. It must also be used when

installing new brake discs or brake discs that

have been removed for any reason and where

the brake disc to hub matching is not evident.

The procedure consists of three parts:

Part 1. Clean mating surfaces

Part 2. Measure and Match brake disc high poi nt to hub low point. If these measurements are not OK, go to Part 3

Part 3. Checking hub mounting face runout

Part 1. Clean Mating Surfaces

Ensure that brake disc and hub mating surfaces are free fr om dirt, corrosion, etc. If requ ired, use fine emery paper to

clean surfaces.

Part 2. Indexing Brake Disc to Hub

1 Install and secure the brake disc onto the h ub with

wheel nuts reversed, to avoid damage to the tapers,

and nip up with a spanner.

2 Number each of the wheel stud holes on the front

surface of the brake disc from 1 to 5. Place a chalk

mark on the end of the wheel stud adjacent to the

number “1” hole (arrow).

NOTE

While the rear disc and caliper are shown, the

procedure for indexing the front brake disc t o the

front hub, is the same.

Figure 5A – 79

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3 Set up a dial indicator on a magnetic bas e and attach

to the strut tube above the brake disc. Position the

pointer 10 – 15 mm inboard from the outer diameter of

the brake disc.

4 Carefully rotate the brake disc and n ote the p oints of

minimum and maximum runout on the dial indicator.

The number of divisions between these two points is

the total indicated runout. Rec ord this figure together

with the number on the brake disc ali gned with the

chalk-marked stud.

5 Remove and reinstall the brake disc with hole number

'2' over the marked stud. Repeat Step 4. This

procedure is to be repeated for all 5 hole positions.

If the lowest assembled disc runout achieved

is more than 0.050 mm (50 micron) then the

hub runout should be checked as detailed in

Part 3 of this procedure. Figure 5A – 80

6 Mount the brake disc to the hub in the stud positio n which recorded the least amount of runout.

Maximum assembled disc and hub

runout at disc outer diameter ............................ 0.05 mm

Part 3. Hub Runout Che ck

1 Clean the front hub face by rubbing lightly with fine

emery paper.

2 Locate the dial indicator on the strut tube and position

the pointer on the hub face about midway between the

spigot and the studs.

NOTE

For this check to be performed with 100 %

accuracy, a flat parallel surface plate attached t o

the hub should be used. However, measuring

runout between each of the wheel studs should

yield adequate results.

3 Carefully rotate the hub by the hub spigot (to avoid

loading the bearing) and note the points of minimum

and maximum runout on the dial indicator. The

number of divisions bet ween these two points is the

total indicated runout.

4 If the runout measured in Step 3 exceeds 0.025 mm

(25 micron) then the hub unit should b e repl aced.

Refer to Section 3A Front Suspension.

Maximum runout at hub face – front hub ........ 0.025 mm

Figure 5A – 81

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Reinstall

1 Reinstall the brake disc over the wheel studs in either the pre-marked/indexed position or the newly indexed

position.

2 Reinstall the brake caliper assembly, refer to 3.4 Front Brake Caliper, in this Section.

3 Depress the brake pedal several times to bring pads into position against disc.

4 Reinstall road wheel in th e original position and secure with the wheel nuts but do not fully tighten.

5 Lower the vehicle to the ground an d tighten the wheel nuts to the specified torque, working in a 'star' pattern, refer

to 2.1 Service Warnings, Cautions an d Notes, in this Section.

Road wheel attaching nut

torque specification...................................110 – 140 Nm

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3.7 Rear Brake Disc

LT Section No. – 04-825

Remove

The brake disc to hub relationship is carefully

matched during production (indexed), to

minimise the effect of a tolerance stack-up,

that could result in disc runout and

subsequent brake shudder.

Carefully mark the relationship of the brake

disc to a wheel stud end for reinstallation. If

this precaution is not taken, then a disc

runout condition could be induced that will

cause brake shudder.

NOTE

If the brake disc is being r emoved to rectify brake

shudder, if the brake disc is to be machined or

replaced, or if brake disc to hub matching is not

evident, the brake disc to the hub must be

indexed, as detailed in this Section.

1 Ensure park brake is fully rele ased.

2 Remove the brake caliper assembl y, refer to

3.5 Rear Brake Caliper, in this Section.

3 It is not necessary to disconnect the brake hose (1)

from the caliper (2). However, the caliper MUST be

supported with tie wire (3) to avoid strain on brake

hose (1).

4 If necessary, jar the brake disc loose by care fully

tapping the disc in the centre bet ween the wheel

studs, with a soft faced hammer (or block of wood and

a hard faced hammer), taking care not to damage the

wheel stud threads.

NOTE

It may be necessary to loosen the park brake

shoe adjustment, to allow the disc to be

removed over the park brake shoes. Refer to

3.9 Park Brake Shoe, Adjust, in this Section. Figure 5A – 82

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Inspect

All Models

1 If the brake disc surface is rusted or lightly scored, resurface disc. Scores less than 0.4 mm deep will not affect

brake performance.

NOTES

• If the disc rotor requires conditioning,

machine or resurface BOTH sides of the

disc. Do not machine or resurface one side

only.

• After machining, the disc finis h should be 0.6

to 1.25 microns and should not be

circumferential i.e. disc finish should be non-

directional. The park brake surface finish

should be 20 microns.

If the minimum brake disc thickness, is

reached during machining operations, then

the disc MUST be replaced .

Figure 5A – 83

• Replace the brake disc if the spec ifications cannot be achiev ed above the minimum disc thickness.

Minimum brake disc rotor thickness

(Replacement required) ....................................13.9 mm

2 If scoring is deep or if disc parameters are out of specification, the disc must be machined or replaced.

MACHING NOTES

• Machine or resurface BOT H sides of disc. Do

not machine or resurface one side only.

• After machining, the brake disc should be

ground to achieve a non-circumferential finish

of 0.6 to 1.25 microns. Park brake drum

surface finish should be 20 microns.

If the minimum brake disc thickness, is

reached during machining operations, then

the disc MUST be replaced .

• Replace the brake disc if specifications

cannot be achieved above the minimum disc

thickness.

Minimum brake disc thicknes s

(replacement required)...................................... 13.9 mm

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NOTES

3 Inspect brake disc as follows:

a Check that surface B is flat within 0.08 mm and

is parallel with surface A within 0.08 mm Total

Indicated Runout (TIR).

b Check that surface C circular run-out is less than

0.08 mm and that surface is square to surface A

within 0.05 mm TIR.

c Check that each brake disc surface is flat within

0.05 mm and is parallel to surface A within 0.085

mm TIR.

d Check that lateral run-out of each braking

surface D is less than 0.05 mm when measured

from surface A as shown or when bolted to the

axle and that rate of change does n ot e xceed

0.03 mm in 30°.

e Check that maximum circumferential thickness

(also referred to as Disc Thickness Variation

(DTV) does not vary by more than 0.013 mm at

any radius when disc is rotated.

Figure 5A – 84

Rear Brake Disc and Hub Indexing Procedure

NOTE

• Brake disc and hub indexing is required so

the minimum installed brake disc runout is

achieved. Brake disc and hub indexing

involves aligning the point of maximum runout

on the hub with the point of least runout on

the brake disc.

• This procedure is to be used when reinsta lling

brake discs that have been removed for

machining off-car. It must also be used when

installing new brake discs or brake discs that

have been removed for any reason and where

the brake disc to hub matching is not evident.

The procedure consists of three parts:

Part 1 Clean mating surfaces

Part 2 Measure and Match brake disc high p oint to hub low point. If these measurements are not OK, go to Part 3

Part 3 Checking hub mounting face runout

Part 1 Clean Mating Surfaces

Ensure that brake disc and hub mating surfaces are free fr om dirt, corrosion, etc. If requ ired, use fine emery paper to

clean surfaces.

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Part 2 Indexing Brake Disc to Hub

1 Fasten the brake disc onto the hub with wheel nuts

reversed to avoid damage to the tapers, and nip up

with a spanner.

2 Number each of the wheel stud holes on the front

surface of the brake disc from 1 to 5. Place a chalk

mark on the end of the wheel stud adjacent to the

number “1” hole (bold arro w).

Figure 5A – 85

3 Set up a dial indicator on a magnetic bas e and attach

to a pre-fabricated mounting plate (1) (refer to

7 Special Tools in this Section for pre-fabricated

mounting plate details) bolted to the caliper attaching

points. Position the pointer of the dial indicator 10 mm

inboard from the outer diameter of the brake disc.

4 Carefully rotate the brake disc and n ote the p oints of

minimum and maximum runout on the dial indicator.

The number of divisions between these two points is

the total indicated runout. Rec ord this figure together

with the number on the brake disc ali gned with the

chalk-marked stud.

If the lowest assembled disc runout achieved

is more than 0.08 mm (80 micron) then the

trunnion hub runout should be checked as

detailed in Part 3 of this procedure.

5 Remove and reinstall brake disc with hole number “2”

over the marked stud and repeat Step 4. This

procedure is to be repeated for all 5 hole positions.

6 Mount the disc to the trunnion hub in the stud position

which recorded the least amount of runout.

Maximum assembled brake di sc and

trunnion hub runout at brake d isc

outer diameter – rear brake disc.......................0.08 mm

Figure 5A – 86

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Part 3 Trunnion Hub Runout Check

1 Clean the front hub face by rubbing lightly with fine

emery paper.

2 Mount a dial indicator on a pre-fabricated mounting

plate bolted to the caliper mounting points, then

position the pointer on the hub face as shown. Refer to

7 Special Tools in this Section for dimensional details

of the mounting plate.

NOTE

For this check to be performed with 100 %

accuracy, a flat parallel surface plate attached t o

the hub should be used. However, measuring

runout between each of the wheel studs should

yield adequate results.

3 Carefully rotate the hub by the wheel studs and note

the points of minimum and maximum runout on the

dial indicator. The number of divisio ns between these

two points is the total indicated runout.

4 If the runout measured in Step 3 exceeds 0.060 mm

(60 micron) then the trunnion assembl y must be

replaced.

Maximum Trunnion hub total

indicated runout (TIR)................................... 0.06 mm

Figure 5A – 87

Reinstall

1 Reinstall the brake disc over the wheel studs in either the pre-marked/indexed position or the newly indexed

position.

2 Reinstall the brake caliper assembly, refer to 3.5 Rear Brake Caliper, in this Section.

3 Depress the brake pedal several times to bring pads into position against disc.

4 Adjust park brake shoe clear ance. Refer to 3.9 Park Brake Shoe, Adjust, in this Section, for details.

5 Reinstall road wheel in th e original position and secure with the wheel nuts but do not fully tighten.

6 Lower the vehicle to the ground an d tighten the wheel nuts to the specified torque, working in a 'star' pattern, refer

to 2.1 Service Warnings, Cautions an d Notes, in this Section.

Road wheel attaching nut

torque specification...................................110 – 140 Nm

7 Road test the vehicle to ensure correct brake operation.

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3.8 Park Brake Lining Wear, Check

1 Remove both rear disc rotors. Refer to 3.7 Rear Brake Disc, in this Section.

2 Check the park brake lining for even wear, both across the shoe and circumferentially around each sho e, for each

lining half, using a vernier caliper or similar.

3 Wear should be even and no thinner than th e specified minimum thickness. If the minimum thickness is at or less

than specified, then the lini ngs must be replaced. The drum section of the r ear disc may also require grinding.

Refer 3.7 Rear Brake Disc, in this Section for specific detail, regarding grinding operations.

Minimum park brake

shoe lining thickness...........................................1.5 mm

NOTE

If one park brake shoe requires replacement,

then both must be replaced.

4 Reinstall rear discs and adj ust the park brake shoe clearances, refer 3.7 Rear Brake Disc and

3.9 Park Brake Shoe, Adjust, both in this Section.

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3.9 Park Brake Shoe, Adjust

1 Using a floor jack under centre of differential carrier,

jack up and support rear of vehicle on safety stands

under rear trailing arms.

2 Remove rear wheel covers (steel wheels) or wheel nut

decorative caps (alloy wheels).

3 Mark relationship of wheels to mounti ng flanges.

4 Remove road wheel attaching nuts and remove

wheels.

5 Release park brake and ens ure that park brake

actuator arms have fully retracted.

If necessary, loosen the front park brake cable

adjustment nut (arrow) with a deep socket, to ensure

slack in the park brake rear cables.

Figure 5A – 88

6 Remove rear brake caliper anc hor plate to trailing arm

attaching bolts (1) (both sides of vehicle), then remove

calipers (2) from discs.

7 Using tie wire, secure calipers to lower end of shock

absorber upper mountings. DO NOT ALLOW

CALIPERS TO HANG BY BRAKE HOSES!

8 Reinstall three wheel nuts, reversed to prev ent

damage to the tapers and ligh tly tighten to secure the

disc in place.

Figure 5A – 89

9 Remove the access hole plug (1). Using a suitable

lever such as a screwdriver, tighten the park brake

shoe screw adjuster, until the disc is locked. Access to

the screw adjuster is through either one of two holes

(1) provided in the disc.

10 Loosen the adjuster 3 – 5 clic ks, then check that the

disc is free and does not drag. Replace the access

hole plug when the adjustme nt procedure has been

completed.

Figure 5A – 90

11 Reinstall brake caliper, install and tighten caliper anchor plate to trailing arm attaching bolts, to the correct torque specification.

Brake caliper anchor plate to

trailing arm attaching bolt

torque specification...............................................85 Nm

12 Reinstall road wheel in th e original position and secure with the wheel nuts but do not fully tighten.

13 Check park brake cable adjustment, refer to 2.2 Park Brake Cable, Adjust, in this Section.

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14 Lower the vehicle to the ground an d tighten the wheel nuts to the specified torque, working in a 'star' pattern, refer

to 2.1 Service Warnings, Cautions an d Notes, in this Section.

Road wheel attaching nut

torque specification...................................110 – 140 Nm

15 Refit wheel covers/wheel nut decorative caps.

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3.10 Park Brake Shoe

LT Section No. – 04-825

Remove

1 Raise the vehicle at the rear and supp ort in a safe manner. Refer to Section 0A General Information for the location

of recommended lifting and support poi nts.

2 Remove the wheel covers or decorative wheel nut caps, then mark the relationship of the road wheel to one of the

wheel studs.

3 Loosen, then remove the road wheel attachi ng nuts, working in a 'star' pattern. Refer 2.1 Service Warnings,

Cautions and Notes in this Section, for detailed information. Remove the road wheel.

4 Release park brake.

5 Remove brake caliper anchor plate to trailing arm

attaching bolts and remove caliper/s from dis c/s.

6 Using tie wire (3), secure the calipers (2) to lower end

of shock absorber upper mountings, as shown. DO

NOT ALLOW CALIPERS TO HANG BY BRAKE

HOSES (1).

7 Index each disc to a wheel stud (bold arrow) using a

felt tipped pen or similar.

8 Remove brake discs.

NOTE

It may be necessary to loosen the park brake

shoe adjustment, to enable disc removal. Refer

to 3.9 Park Brake Shoe, Adjust, in this Section.

Figure 5A – 91

9 Remove park brake shoe by g r asping each end as

shown. Push up on one end of the shoe, dislodging

the end from the actuator pin and the shoe from the

retaining clip.

Figure 5A – 92

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10 Using a screwing motion, rotate the park brake shoe

around the trunnion flange to remove it from the

vehicle.

11 Remove the park brake shoe spring retainer by prisi ng

from the rear disc shield, with a screwdriver or similar

lever.

12 If required, the actuator screw adjuster and pins can

be removed at this point, but the body and remaining

components are not able to be removed without first

removing the rear disc shield. For this operation, refer

to 3.12 Rear Disc Brake Dust Shield in this Section.

Figure 5A – 93

Reinstall

1 Apply an NLGI No. 2 lithium soap based EP grease with molybdenum disulphide, such as Shell Retinax HDX2

grease or BP Energrease LMS-EP 23 (or eq uivalent) to the adjusting screw and pins.

2 Fully wind screw into sleeve and install into the adjuster body.

3 Install the park brake shoe over the trunnion flange.

4 With one shoe end located on the adjuster pin, roll the

shoe to engage the other end onto the other pin.

Figure 5A – 94

5 Reinstall park brake shoe ret aining spring clip, by

sliding it into place, ensuring that the sprin g clip is

correctly located by the tangs in the rear brake shield.

Figure 5A – 95

6. Reinstall brake discs, alig ning marks made on removal.

7. Adjust park brake shoe to disc clearance. Refer to 3.9 Park Brake Shoe, Adjust, in this Section.

8 Reinstall caliper anchor plate attaching bolts and tighten to the correct torque specification.

Rear brake caliper anc hor plate

bolt torque specification........................................85 Nm

9 Adjust park brake cable, refer to 2.2 Park Brake Cable, Adjust, in this Section.

10 Reinstall road wheel in th e original position and secure with the wheel nuts but do not fully tighten.

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11 Lower the vehicle to the ground an d tighten the wheel nuts to the specified torque, working in a 'star' pattern, refer

to 2.1 Service Warnings, Cautions an d Notes, in this Section.

Road wheel attaching nut

torque specification...................................110 – 140 Nm

12. Refit wheel covers/wheel nut decorative caps.

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3.11 Front Disc Brake Shield

LT Section No. – 04-805

NOTE

Refer to Section 3A Front Suspension for this procedure

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3.12 Rear Disc Brake Dust Shield

LT Section No. – 04-825

ATTENTION

The following fasteners MUST be replaced when performing these operations:

 Lower rear disc brake shield to trailing arm bolts.

Remove

1 Raise the rear of the vehicle and sup port in a safe manner. Refer to Section 0A General Information for the location

of recommended lifting and support poi nts.

2 Remove the decorative wheel nut caps, then mark the relationship of the road wheel to one of the wheel studs.

3 Loosen, then remove the road wheel attachi ng nuts, working in a 'star' pattern. Refer 2.1 Service Warnings,

Cautions and Notes in this Section, for detailed information. Remove the road wheel.

4 Release park brake.

5 Thoroughly clean around brake hose to pipe

connection at backing plate. Disconnect brake pipe (4)

from the brake hose (3) at backing plate bracket (2)

and remove brake hose retaining clip (2).

Figure 5A – 96

6 Remove brake caliper anchor plate to trailing arm

attaching bolts and remove caliper from disc.

7 Using wire, tie up caliper/s to the lo wer end o f the

shock absorber upper mounti ng/s. DO NOT ALLOW

THE CALIPER/S TO HANG BY THE BRAKE HOSE/S.

Figure 5A – 97

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8 Index each disc to a wheel stud using a felt tipped pen

or similar, as indicated by the bold arrow.

9 Remove brake disc/s.

NOTE

It may be necessary to loosen the park brake

shoe adjustment, to enable disc removal. Refer

to 3.9 Park Brake Shoe, Adjust, in this Section.

10 Disconnect the park brake cable from the actuator

arm. See 2.12 Rear Park Brake Cable/s, in this

Section, for details.

Figure 5A – 98

11 Remove trailing arm trunnion flange and trunnion assembly, refer to Section 4B1 Rear Final Drive and Drivesh afts ,

for the necessary procedure.

NOTE

Because the trunnion flange removal procedure

will cause the rear wheel bearing to be brinelled,

it must be replaced on reassembly. Also refer to

Section 4B1 Rear Final Drive and Drive Shafts,

for the necessary procedure for this service

operation.

12 Following the removal of the trunnion and bearing assembly, the backing plate will be free to be removed, together

with the parking brake shoe assembly.

13 Remove park brake shoe assembly. Refer to 3.10 Park Brake Shoe, in this Section.

14 To disassemble the park brake actuator assembly (2,

3 and 4) from the rear disc shield, support the disc

shield to minimise distortion, then carefull y press the

actuator assembly from the lower extruded bolt hole

sections of the disc plate.

Figure 5A – 99

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Reinstall

Reinstallation of the rear disc shield is the reverse to the

removal procedures, except for the following points:

1 As the removed actuator assembly can easily be

disassembled, the view shown, details the

relationships of each, in an ex ploded view.

2 While supporting the rear dis c brake shield, install the

actuator assembly to the extruded bolt hole sections,

after ensuring that the actuator mechanism is correctly

assembled.

Legend

1 Adjusting Screw

2 Adjusting Ratchet Wheel

3 Actuator Body

4 Parking Brake Actuator Lever

5 Brake Shoe Anchor

6 Washer

7 Pin

8 Ratchet Wheel Spring

Figure 5A – 100

3 Reinstall trunnion to the trailing arm, using a new wheel bea ring. For the required procedu r es refer to

Section 4B1 Rear Final Drive and Drive Shafts, for the necessary procedure.

4 Reinstall the two upper rear disc brake shield to trailing arm attaching Torx bit headed bolts. Do not tighten at this

stage.

5 Install two NEW lower rear disc brake shield to trailing arm bolts.

6 Tighten the four rear disc brake shield to trailing arm attaching bolts to the correct torque specifications.

Upper rear disc brake shield to

trailing arm bolt torque specification......................75 Nm

 Lower rear disc brake shield to

trailing arm bolt torque specification......................85 Nm

7 Reinstall the park brake shoe. Refer to 3.10 Park Brake Shoe, in this Section.

8 Reinstall the rear disc, aligning the marks made before removal and adjust the park brak e shoe, refer to

3.9 Park Brake Shoe, Adjust, in this Section for the procedure.

9 Install and tighten brake cali per anchor plate to trailing arm attaching bolts to the correct torque specification.

Brake caliper anchor plate to

trailing arm bolt torque specification......................85 Nm

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10 Reinstall the caliper hose (3) to the backing plate

bracket (2) and secure with the retaining clip (1).

11 Reinstall the brake pipe (4) to the caliper hose (3) and

tighten to the correct torque specifications.

Brake pipe flare nut to caliper

brake hose torque specification ............................15 Nm

Figure 5A – 101

12 Reinstall road wheel in th e original position and secure with the wheel nuts but do not fully tighten.

13 Lower the vehicle to the ground an d tighten the wheel nuts to the specified torque, working in a 'star' pattern, refer

to 2.1 Service Warnings, Cautions an d Notes, in this Section.

Road wheel attaching nut

torque specification...................................110 – 140 Nm

14 Reinstall the decorative centre wheel cover.

15 Check for brake fluid leaks, repair as necessary.

16 Road test vehicle to ensure correct brake operatio n.

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4. Diagnosis

Symptom Cause

X – Indicates Probable Cause

XX – Indicates a More Possible Cause

xcessive Brake Pedal Travel

rake Pedal Travel Gradually Increases

xcessive Brake Pedal Effort

xcessive Braking Action

rakes Slow to Respond

rakes Slow to Release

rakes Drag

neven Braking Action (Side to Side)

neven Braking Action (Front to Rear)

craping Noise from Brakes

rakes Squeak During Applica t ion

rakes Squeal During a Stop

rakes Chatte

rakes Groan at End of Stop

rake Tell-tale Lamp Glows During a Stop

Leaking Brake Line or Connection X X X

Leaking Caliper or Piston Line X X X X X

Leaking Master Cylinder X XX X

Air in Brake System XX X X

Contaminated or Improper Brake Fluid X X X X

Leaking Vacuum System XX X

Restricted Air Passage in Vacuum Booster X XX X

Damaged Vacuum Booster X X X X XX

Improperly Assembled Vacuum Booster Valving X X X X XX

Worn Out Disc Pads – Replace X X X X X X X X

Uneven Disc Pad Wear – Replace or Correct X X X X X XX X

Contaminated Disc Pad – Replace XX XX XX X X X X

Heat Spotted or Scored Brake Discs X X X X X XX X

Out-of-Parallel Brake Discs XX

Excessive Brake Disc Run-Out X

Brake Assembly Attachments – Missing or Loose X X X X X X X X

Restricted Brake Fluid Passage or Sticking Caliper

Piston X X X X X X X

Brake Pedal/Linkage Binding or Interference X X X XX

Improperly Adjusted Parking Brake X

Incorrect Front Wheel Alignment X XX

Incorrect Tyre Pressures X X

Wheel Bearing Clearance Excessive X X

Loose Front Suspension and/or Components X XX X X

Out-of-Balance Wheel Assemblies XX

Operator Riding Brake Pedal X X X X X X

Table 1

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5 Specifications

Brake Fluid

Type.............................................................................................................Super DOT 4 Plus

Brake Booster

Make.......................................................................................................... Mando Corporation

Type...........................................................................................Tandem, Vacuum Suspended

Size...............................................................................................................20.3 and 22. 9 cm

Master Cylinder

Make.......................................................................................................... Mando Corporation

Type.............................................................................................................................Tandem

Bore diameter (nominal)................................................................................................26 mm

Front Disc

Type..........................................................................................................................Ventilated

Diameter (nominal)....................................................................................296 + 0.0 – 0.2 mm

Thickness ........................................................................................................28.0 ± 0.15 mm

Lateral Runout (maximum)..........................................0.04 mm Total Indicated Run-out (TIR)

Minimum thickness, requiring replacement.................................................................25.0 mm

Front Caliper

Make................................................................................................................................. PBR

Type................................................................................................Twin piston, sliding caliper

Bore diameter (nominal).............................................................................................42.0 mm

Front Disc Pad

Material ........................................................................................Organic, non-asbestos

Minimum Thickness before Replacement ...............................................................2 mm

Rear Disc

Type..................................................................................................................................Solid

Diameter (nominal).............................................................................................286 ± 0.2 mm

Thickness ...................................................................................................15.9 mm ± 0.2 mm

Lateral Runout (maximum)....................... (Rate of change 0.03 mm in 30° rotation) 0.05 mm

Minimum thickness, requiring replacement.................................................................13.9 mm

Rear Caliper

Make................................................................................................................................. PBR

Type..............................................................................................Single piston, sliding caliper

Bore diameter (nominal).............................................................................................45.0 mm

Rear Disc Pad

Material ........................................................................................Organic, non-asbestos

Minimum Thickness before Replacement ...............................................................2 mm

Drum Park Brake

Make................................................................................................................................. PBR

Type................................................................Banksia, single shoe, cable and lever operated

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Drum

Inside Diameter (nominal)...................................................................................190 mm

Maximum out of square (TIR with disc surface).................................................0.05 mm

Maximum out of round........................................................................................0.08 mm

Linings

Type.................................................................................................................... Bonded

Width.....................................................................................................................25 mm

Thickness.............................................................................................................3.5 mm

Minimum Thickness before Replacement ............................................................1.5 mm

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6 Torque Wrench Specifications

ATTENTION

 Fasteners must be repl aced after loosening.

 Vehicle must be at curb height before final tightening.

 Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock and

should only be re-used once. If in doubt, replacement is recommended.

Accelerator pedal sensor bracket attaching nut.................................25 Nm

Brake Bleeder Nipple (All)..................................................................12 Nm

Brake booster retaining nut................................................................25 Nm

 Brake caliper guide pin bolt................................................................32 Nm

Brake fluid reservoir attaching screw................................................2.5 Nm

Brake hose to caliper banjo bolt (all)..................................................35 Nm

Brake pedal support to brake booster bolt.........................................25 Nm

Brake pedal support shaft nut ...........................................................55 Nm

Brake pipe to brake hose flared nut (All positions).............................15 Nm

Brake pipe harness bracket to dash panel bolt..................................10 Nm

Brake pipe to master cylinder flare nut ..............................................14 Nm

 Front brake caliper anchor bolt..........................85 Nm, plus 45° turn angle

 Front hub to steering knuckle bolt....................................................130 Nm

Front park brake cable plate retaining screw....................................2.0 Nm

Lower brake pipe shield to floor bolt ..................................................10 Nm

Lower brake pipe shield to floor nut.....................................................2 Nm

Master cylinder attaching nut.............................................................10 Nm

Master cylinder to bracket bolt...........................................................10 Nm

Master cylinder bracket to strut tower attaching nut.............................8 Nm

Master cylinder reservoir retaining screw..........................................2.5 Nm

Outer front park brake cable bracket retaining bolt............................25 Nm

Park brake lever bolt..........................................................................50 Nm

Park brake warning lamp switch retaining screw.................................2 Nm

 Rear brake caliper anchor plate bolt..................................................85 Nm

Rear disc brake shield to trailing arm...............Upper bolt.................75 Nm

 Lower bolt.................85 Nm

Road wheel attaching nut ......................................................110 – 140 Nm

 Steering knuckle to strut attaching nuts Stage 1..............................85 Nm

Stage 2............................100 Nm

Stage 3..............Turn through 90°

Service and Park Braking Systems Page 5A-86

Page 5A-86

7 Special Tools

Tool Number Illustration Description Tool Classification

AU 534

Torque Limiting Socket

Used in conjunction with an impact

gun to tighten wheel nuts.

Previously released.

Essential

E 7115

Angle Wrench

1. Previously released as Tool N o.

394.

2. Used to apply an angle torque to

fasteners when required.

Previously released.

Available

J23738-A

Hand Vacuum Pump

Used to apply a vacuum for

diagnostics and emptying the master

cylinder reservoir. Also commerciall y

available.

Previously released.

Mandatory

Dial Indicator Plate

Retailer fabricated from 6 mm Mild Steel Plate.

NOTE

If using the caliper bolts to attach the plate to the

trunnion, a 17 mm spacer will need to be installed

on each bolt, prior to installing .