SECTION D - BRAKES

CAUTION:

HSV vehicles are equipped with a Supplemental Restraint System (SRS). An SRS

consists of seat belt pre-tensioners (fitted to all front seats), and a driver’s-side air

bag or a driver’s-side air bag AND a passenger’s-side air bag. Refer to CAUTIONS,

Section 12M, before performing any service operation on or around SRS

components, the steering mechanism or wiring. Failure to follow the CAUTIONS

could result in personal injury or unnecessary SRS system repairs.

PURPOSE

The purpose of this section is to provide information on the Brak e Systems fitted to HSV VT and HSV VS Models.

This information is designed to supplement that given in the Holden VT and VS Series Service Information CD’s,

and details are given where differences occur between the HSV models and standard Holden models. A series of

instruction drawings describe the design changes and indicate specific part numbers, fitting instructions and

relevant notes for vehicle servicing.

NOTE:

If specific technical data on a HSV model is not contained in this supplement, obtain data for that model from the

Holden VT Series Service Information CD. References are made throughout this section to Holden VT Series

Service Information CD, to assist in providing information for specific service operations.

CAUTION:

W hen hois ting (or j acking) HSV models , ensure that the lifting head of the hoist lifts on the chas sis before the arm

of the hoist contacts the side-skirt

1. GENERAL

Brake systems fitted to HSV VT and HSV VS models employ the vacuum boosted, four-wheel-disc concept

operating through a tandem master cylinder. This tandem arrangement provides separate braking systems to the

front and rear wheels which in turn, provides adequate brak ing (to the f ront or r ear wheels) if a f ault occur s in either

system. HSV VT and HSV VS models are also equipped with the BOSCH Anti-lock Braking System (ABS) as

standard. Inspection, replacement and testing of the ABS must be carried out in accordance with the procedures

detailed in the Holden VT Series Service Information CD, refer Section 12L ABS & ABS/ETC.

CAUTION:

Whenever any component of the ABS is disturbed during service operations, it is vital that the complete ABS is

check ed using the procedure detailed in the Holden VT Series Service Infor mation CD, ref er Section 12L ABS &

ABS/ETC.

Five alternate brake systems are fitted to HSV VT and VS models . Three of thes e s ystems have been developed by

HSV to satisfy the need for more efficient brakes on high-performance vehicles; the two other systems used are

GMHA systems fitted by Holden during the vehicle build-up. A description of these brake systems and their

Standard (S) and Optional (O) application is contained in succeeding paragraphs.

TABLE D-1 BRAKE SYSTEMS

MODEL VT

PREMIUM VT

PERFORMANCE VS

PREMIUM GMHA

VS GMHA

220I

BLUEPRINT S

GTS 220i

SENATOR 220i O

GRANGE 215 S

GRANGE 185i

SENATOR 195i

CLUBSPORT

MANTA 195i

MALOO 185i

2. VT PERFORMANCE BRAKE SYSTEM

VT Performance brakes are standard fit on GTS and Senator 220i vehicles. The Performance system is also an

optional fit on other HSV VT models listed in the Table D-1. The new VT Performance system - illustrated in

Figures D-1 and D-2 - is a further development of brake systems developed for earlier HSV models. The major

components of the new Performance System are as follows:

Front ventilated disc of 330mm x 32mm, (PN 05A-970701).

Front Caliper Assemblies are twin piston floating of 40.5mm diameter, (PNs LH 05A-970705, RH 05A-970706 ).

Bracket Caliper Mounting Brackets, (PNs LH 05A-970713, RH 05A-970714).

Front Brake Hose, (PNs LH 05F-970702, RH 05F-970701).

Rear ventilated disc of 315mm x 18mm, (PN 05B 970701).

Rear Caliper are single piston floating of 45mm diameter, ( PNs LH 05B-970705, RH 05B-970706).

Rear brake hose, (05F-970703).

Pad material is BM962 front and rear.

Figure D-1 - VT Performance Brake System - Front

Figure D-2 - VT Performance Brake System - Rear

3. VT PREMIUM BRAKE SYSTEM

The HSV VT Premium Brake System, see Figures D-3 and D-4, is fitted as standard equipment on VT Blueprint

models, and is available as an option on other VT models listed in Table D-1. Components of the VT Premium

system (which replace VT Performance components) are as follows;-

Front ventilated and cross drilled Disc of 343mm x 32mm, ( PN 05A-970712)

Front four piston opposed Caliper Assembly - 2 pistons of 38.1mm and 2 pistons of 41.3mm diameter,

( PNs 05A-970710 and 05A-970711)

Rear ventilated and cross drilled brake disc 315mm X 18mm (PN 05B-970701)

Rear four piston opposed Caliper Assembly with piston size of 28.57mm diameter (PNs 05B-970709 and

05B-970710)

Pad material is PX987, front and rear.

Figure D-3 - VT Premium Brake System - Front

Figure D 4 - VT Premium Brake System - Rear

4. GMHA BRAKE SYSTEMS

The HSV Grange 185i Sedan, Maloo Utility, Senator 200 models, ClubSport and Manta are fitted with Holden

brakes and these brake systems are to be serviced in accordance with the procedures in the Holden VT Series

Service Information CD, refer Section 5A STANDARD BRAKES. In addition, the rear brake hose and the rear

brake bias valve linkage on the Maloo Utility must be adjusted as follows:

Rear Brake Hose Retention. The rear brake hose is retained in position by a Herbie clip to ensure that the

hose doesn’t make contact with the exhaust system. This requirement is shown in Figure D-5.

Rear brake bias valve linkage. The Maloo 185i Utility is equipped with a HSV design rear brake bias valve

linkage assembly that operates in conjunction with the HSV specific panhard rod. It is designed with a specific

length linkage nut to accommodate the lowered ride height. The load sensing valve link chain dimension must

be measured before disconnecting the link chain for service. The link chain assembly must be adjusted to

maintain the previously measured dimension upon reassembly. Refer Figure D-6.

CAUTION:

IT IS CRITICAL FOR SAFETY THAT THE LINK CHAIN IS SET TO THE CORRECT LENGTH AND THAT THE

SPRING AND CLIP ARE CORRECTLY INSTALLED AS SHOWN IN FIGURES D-5 AND D-6.

Figure D-5 - Rear Brake Hose Retention

Figure D-6 - Rear Brake Bias Valve Linkage

5. VS PREMIUM BRAKE SYSTEM

Grange 215i Sedans ar e equipped with the HSV VS Premium Brake System which is s hown in dr awings Figur es D-

7 and D-8. The HSV design components in this system are as follows:

328mm x 28mm ventilated front disc/hub assemblies.

280mm x 20mm ventilated rear disc assemblies.

Twin piston front calipers.

Front caliper mounting brackets and bolts.

Front brake hose assembly to suit relocated caliper fitting.

Large diameter single piston rear calipers.

Rear brake hoses

BM 962 brake pads

NOTE:

1. The front dust shield is not fitted.

2. Vehicles fitted with ABS retain the factory fitted master cylinder.

3. Rear brake pad backing plates have been revised from 5mm to 6mm to improve rotor wear allowance.

Figure D-7 - HSV VS Premium Brake System - Front

Figure D-8 - HSV VS Premium Brake System - Rear

6. SERVICE OPERATIONS

Although HSV brake systems have different fittings and components, the general service principles are the same as

those which apply to Holden standard brake systems. The important differences between Holden brake systems

and HSV systems ar e the component parts and the specified wear lim its for those parts . Drawings of specif ic HSV

brake systems and component part numbers are included in this section and wear limits have also been specified

where required.

6.1 PAD REPLACEMENT

Refer to appropriate drawings in this section or in Holden Service Manual. Ensure that the following im portant notes

are observed and replace brake pads in accordance with the procedures in the Holden VT Series Service

Information CD, refer Section 5A STANDARD BRAKES.

IMPORTANT NOTES ON BRAKE PAD REPLACEMENT

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

Pads should be replaced if there is less than 3mm of lining material remaining or if pads are damaged.

Pads m ust be replaced as a full set of 4. Ensure pad m aterial is c orrect specif ication. Do not m ix pad m aterial

front to rear. Use genuine HSV replacement parts to ensure correct pad material is used.

Before fitting new pads check that all pads are fitted with insulating material.

When replacing pads in VT Perf or manc e brakes, ens ur e that s hims and s pring ar e f ully clipped into position so

that they are clear of the rotor. Carefully lower the body over the pads and bracket ensuring the pads are

engaged with spring so that they are fr ee to slide. Ens ur e Piston Boot is not c aught between the Piston and the

inner pad. Fit new guide bolt through the lower hole and tighten to a torque of 30-34 Nm.

6.2 CALIPER OVERHAUL

Refer to appropriate drawings in this section or in Holden Service Manual. Ensure that the following im portant notes

are observed and over haul calipers as detailed in the Holden VT Series Ser vice Inform ation CD, ref er Sectio n 5A

STANDARD BRAKES.

NOTES ON CALIPER OVERHAUL

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

Remove the pistons by directing light air pressure into the brake hose port, and progressively increase until

piston is forced out of bore.

CAUTION:

Caution is necessary to avoid physical injury. Piston may be ejected with considerable force due to air pressure.

Use packing to prevent piston damaging body of caliper.

6.3 BRAKE DISCS

Refer to appropriate drawings in this section or in Holden Service Manual. Ensure that important notes are observed

and overhaul discs as detailed in Holden VT Series Service Information CD, refer Section 5A STANDARD

BRAKES.

CAUTION:

Do not remove mounting bracket from the brake caliper unless the bracket requires service. It is critical for safety

that the bolts holding the mounting bracket to the caliper if removed, are correctly reinstalled.

Brake Disc Wear Limits. The minimum thickness for discs fitted to standard Holden brakes is cast in the hub of

the disc and is specified in the relevant Holden Service Manual. The minimum thickness for brake discs fitted to

HSV brake systems is stamped into the edge of the disc. For information, the new and minimum thicknesses of

discs used in HSV brake systems are tabulated below.

DISC LOCATION NEWTHICKNESS MINIMUMTHICKNESS

VT PREMIUM

FRONT

REAR 32.0mm

18.0mm 30.0mm

16.0mm

VT PERFORMANCE

FRONT

REAR 32.0mm

18.0mm 30.0mm

16.0mm

VS PREMIUM

FRONT

REAR 28.0mm

20.0mm 25.0mm

18.0mm

6.4 SERVICE PARTS

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

replacing brake pads because of the various types of lining material used. Complete brake assemblies, front and

rear discs, calipers and attachment parts have also been identified as replacement parts and these items are

available from HSV: these parts are listed in the following paragraphs or referenced in enclosed drawings.

VS PREMIUM REPLACEMENT PARTS.

Refer to Figures D-7 and D-8 for major component part numbers. Service kits for the VS Premium brake system

are listed below:

FRONT CALIPERS

05A-121916 CALIPER HYDRAULIC REPAIR KIT COMPRISING:

2 OFF PISTON SEALS

2 OFF PISTON BOOTS

1 OFF BLEED SCREW CAP

05A-121917 CALIPER HOUSING ASSY R.H. COMPRISING:

1 OFF HOUSING R.H.

2 OFF PISTONS

2 OFF PISTON SEALS

2 OFF PISTON BOOTS

1 OFF BLEED SCREW

1 OFF BLEED SCREW CAP

05A-121918 CALIPER HOUSING ASSY L.H. COMPRISING:

1 OFF HOUSING L.H.

2 OFF PISTONS

2 OFF PISTON SEALS

2 OFF PISTON BOOTS

1 OFF BLEED SCREW

1 OFF BLEED SCREW CAP

05A-121919 PISTON

05A-121920 BLEED SCREW

05A-121921 PAD RETAINING CLIP

05A-121922 "E" - CLIP

05A-121923 ANCHOR PLATE R.H.

05A-121924 ANCHOR PLATE L.H.

PAD KIT COMPRISING (BM962)

1 OFF PAD ASSY INNER L.H.

1 OFF PAD ASSY OUTER L.H.

1 OFF PAD ASSY INNER R.H.

1 OFF PAD ASSY OUTER R.H.

2 OFF RETAINING PIN

2 OFF "E" - CLIP

REAR CALIPERS

05B-121906 MAJOR SERVICE KIT COMPRISING:

1 OFF PISTON SEAL

1 OFF PISTON BOOT

1 OFF BLEED SCREW CAP

2 OFF GUIDE PINS

2 OFF GUIDE PIN BOOTS

2 OFF GUIDE PIN BOLTS

05B-121907 HYDRAULIC SERVICE KIT COMPRISING:

1 OFF PISTON SEAL

1 OFF PISTON BOOT

1 OFF BLEED SCREW CAP

2 OFF GUIDE PIN BOLTS

05B-211917 CALIPER HOUSING ASSY R.H. COMPRISING:

1 OFF HOUSING R.H.

1 OFF PISTON

1 OFF PISTON SEAL

1 OFF PISTON BOOT

1 OFF BLEED SCREW

1 OFF BLEED SCREW CAP

05B-211918 CALIPER HOUSING ASSY L.H. COMPRISING:

1 OFF HOUSING L.H.

1 OFF PISTON

1 OFF PISTON SEAL

1 OFF PISTON BOOT

1 OFF BLEED SCREW

1 OFF BLEED SCREW CAP

05B-121910 PISTON

05B-121911 BLEED SCREW

05B-211919 ANCHOR PLATE

PAD KIT COMPRISING (BM962)

1 OFF PAD ASSY INNER L.H.

1 OFF PAD ASSY INNER R.H.

2 OFF PAD ASSY OUTER

VT PERFORMANCE REPLACEMENT PARTS

Refer to Figures D-1 and D-2 for major component part numbers. Service kits for the VT Performance brake

system are listed below:

FRONT CALIPERS

05A-970730 FRONT HYDRAULIC REPAIR KIT COMPRISING

2 OFF SEALING RING

2 OFF PISTON BOOT

1 OFF BLEED SCREW PROTECTOR COVER

2 OFF GUIDE PIN BOOT

05A-970731 FRONT CALIPER HOUSING ASSEMBLY RH COMPRISING

1 OFF CALIPER BODY RH

1 OFF ABUTMENT BODY

2 OFF PAD ABUTMENT SHIM

2 OFF SEALING RING

2 OFF PISTON BOOT

2 OFF PISTON

1 OFF BLEED SCREW PROTECTOR COVER

1 OFF BLEED SCREW

1 OFF ANTI RATTLE SPRING

2 OFF GUIDE PIN BOOT

2 OFF GUIDE PIN

2 OFF GUIDE PIN BOLT

O5A-970732 FRONT CALIPER HOUSING ASSEMBLY LH COMPRISING

1 OF CALIPER BODY LH

1 OFF ABUTMENT BODY

2 OFF PAD ABUTMENT SHIM

2 OFF SEALING RING

2 OFF PISTON BOOT

2 OFF PISTON

1 OFF BLEED SCREW PROTECTOR COVER

1 OFF BLEED SCREW

1 OFF ANTI RATTLE SPRING

2 OFF GUIDE PIN BOOT

2 OFF GUIDE PIN

2 OFF GUIDE PIN BOLT

05A-970733 PISTON BRAKE

05A-970734 BLEED SCREW

05A-970735 PAD ABUTMENT SHIM

05A-970736 ANTI RATTLE SPRING

05A-970737 GUIDE PIN

05A-970738 GUIDE PIN BOLT

05A-970704 BRAKE PAD KIT BM962 COMPRISING

2 OFF OUTER PAD ASSEMBLY BM962

2 OFF INNER PAD ASSEMBLY BM962

4 OFF GUIDE PIN BOLT

REAR CALIPERS

Servicing procedures and servicing kits for the VT Performance Rear Caliper are exactly the same as for the

standard VT Holden Rear Caliper. Therefore, when servicing the VT rear caliper, refer to the procedures in the

Holden VT Series Service Information CD, Section 5A STANDARD BRAKES.

VT PREMIUM REPLACEMENT PARTS

Refer to Figures D-3 and D-4 for major component part numbers. Service kits for the VT Premium brake system

are listed below:

FRONT CALIPERS

05A-970717 FRONT CALIPER HYDRAULIC REPAIR KIT COMPRISING

2 OFF SEALING RING 1 5/8

2 OFF SEALING RING 1 ½

4 OFF DUSTBOOT

4 OFF DUSTBOOT RETAINING RING

2 OFF BLEED SCREW DUST CAP

2 OFF CALIPER BRIDGE SEAL

05A-970718 FRONT CALIPER HOUSING ASSEMBLY RH COMPRISING

1 OFF CALIPER BODY -INNER HALF RH

1 OFF CALIPER BODY -OUTER HALF RH

2 OFF SEALING RING 1 5/8

2 OFF SEALING RING 1 ½

2 OFF CALIPER PISTON 1 5/8

2 OFF CALIPER PISTON 1 ½

4 OFF DUSTBOOT

4 OFF DUSTBOOT RETAINING RING

1 OFF PAD RETAINER

2 OFF CALIPER BRIDGE SEAL

2 OFF PAD WEAR STRIP RH

4 OFF PAD WEAR STRIP SCREW

2 OFF PAD WEAR STRIP LH

4 OFF CALIPER BOLTS

1 OFF PAD RETAINING BOLT

2 OFF BLEED SCREW

2 OFF BLEED SCREW DUST CAP

05A-970719 FRONT CALIPER HOUSING ASSEMBLY LH COMPRISING

1 OFF FRONT CALIPER BODY - INNER HALF LH

1 OFF FRONT CALIPER BODY OUTER HALF LH

2 OFF SEALING RING 1 5/8

2 OFF SEALING RING 1 ½

2 OFF CALIPER PISTON 1 5/8

2 OFF CALIPER PISTON 1 ½

4 OFF DUSTBOOT

4 OFF DUSTBOOT RETAINING RING

1 OFF PAD RETAINER

2 OFF CALIPER BRIDGE SEAL

2 OFF PAD WEAR STRIP RH

4 OFF PAD WEAR STRIP SCREW

2 OFF PAD WEAR STRIP LH

4 OFF CALIPER BOLTS

1 OFF PAD RETAINING BOLT

2 OFF BLEED SCREW

2 OFF BLEED SCREW DUST CAP

05A-970720 PISTON 1 5/8

05A-970721 PISTON 1 ½

05A-970722 BLEED SCREW

05A-970723 PAD RETAINER

05A-970724 CALIPER BOLT

05A-970725 PAD RETAINER BOLT

05A-970726 PAD WEAR STRIP RH

05A-970727 PAD WEAR STRIP LH

05A-970728 PAD WEAR STRIP SCREW

05A-970729 BRAKE PAD KIT (PX987) COMPRISING

4 OFF BRAKE PAD (PX987)

REAR CALIPERS

05A-970713 FRONT CALIPER HYDRAULIC REPAIR KIT COMPRISING

4 OFF SEALING RING

4 OFF DUSTBOOT

4 OFF DUSTBOOT RETAINING RING

2 OFF BLEED SCREW DUST CAP

2 OFF CALIPER BRIDGE SEAL

05B-970714 REAR CALIPER HOUSING ASSEMBLY RH COMPRISING

1 OFF CALIPER BODY -INNER HALF RH

1 OFF CALIPER BODY -OUTER HALF LH

4 OFF SEALING RING 1 1/8

4 OFF CALIPER PISTON 1 1/8

4 OFF DUSTBOOT

4 OFF DUSTBOOT RETAINING RING

1 OFF PAD RETAINER

2 OFF CALIPER BRIDGE SEAL

2 OFF PAD WEAR STRIP RH

2 OFF PAD WEAR STRIP LH

4 OFF PAD WEAR STRIP SCREW

4 OFF CALIPER BOLTS

1 OFF PAD RETAINING BOLT

2 OFF BLEED SCREW

2 OFF BLEED SCREW DUST CAP

05B-970715 REAR CALIPER HOUSING ASSEMBLY LH COMPRISING

1 OFF CALIPER BODY -INNER HALF RH

1 OFF CALIPER BODY -OUTER HALF LH

4 OFF SEALING RING 1 1/8

4 OFF CALIPER PISTON 1 1/8

4 OFF DUSTBOOT

4 OFF DUSTBOOT RETAINING RING

1 OFF PAD RETAINER

2 OFF CALIPER BRIDGE SEAL

2 OFF PAD WEAR STRIP RH

2 OFF PAD WEAR STRIP LH

4 OFF PAD WEAR STRIP SCREW

4 OFF CALIPER BOLTS

1 OFF PAD RETAINING BOLT

2 OFF BLEED SCREW

2 OFF BLEED SCREW DUST CAP

05B-970716 PISTON 1 1/8

05A-970722 BLEED SCREW

05B-970717 PAD RETAINER

05B-970718 CALIPER BOLT

05B-970719 PAD RETAINER BOLT

05B-970720 PAD WEAR STRIP RH

05B-970721 PAD WEAR STRIP LH

05B-970728 PAD WEAR STRIP SCREW

05B-970722 BRAKE PAD KIT (PX987) COMPRISING

4 OFF BRAKE PAD (PX987) REAR