SECTION 5A - STANDARD BRAKES

CAUTION:

This vehicle will be equipped with either a driver's side only or driver's and front

passenger's side AIR BAGS. An AIR BAG is a Supplemental Restraint System (SRS).

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 air bag deployment, resulting in possible personal injury

or unnecessary SRS system repairs.

CAUTION:

This vehicle may be equipped with LPG (Liquefied Petroleum Gas). As this fuel is

heavier than air in the vapour form and in the interests of safety, the LPG fuel system

should be isolated by turning 'OFF' the manual service valve and then draining the

LPG service lin es, before any service wo rk is carried out o n the v ehicle. Refer t o the

LPG leaflet included with the Owner's Handbook for details or LPG Section 2 for

more specific servicing information.

CAUTION:

Whenever any component that forms part of the ABS (if fitted), is disturbed during

Service Operations, it is vital that the complete ABS system is checked, using the

procedure as detailed in DIAGNOSIS, ABS FUNCTION CHECK, in Section 12L ABS &

ABS/ASR.

1. GENERAL INFORMATION

1.1 GENERAL DESCRIPTION

Except for those vehicles equipped with ABS as standard equipment, the front and rear disc brakes on VT Series

vehicles, are served by separate brake circuits by means of a tandem master cylinder, working through a vacuum

booster. The dual brake circuit arrangement is designed to provide adequate braking, should a fault occur in either

circuit.

All VT Series vehicles are fitted with a Stepped Tandem, Vacuum Suspended type brake booster and a 25.4 mm

bore master cylinder, regardless of the brake system used. The brake booster can not be serviced and must be

replaced if defective.

All VT models are fitted with ventilated discs at the front and solid discs at the rear. The brake calipers are the

sliding, reaction type, with twin pistons in the front calipers and single in the rear.

The rear brake backing plate assembly 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.

The single shoe, ‘Banksia’ park brake is a drum type with a manual adjustment incorporated into the design. The

park brake is operated by two separate cables at the rear, connected to an equaliser bracket. Park brake

application force is applied to this equaliser bracket, via a single cable connected to the floor mounted, button

release, park brake lever. Adjustment of the parking brake cables is provided for, by a threaded end on the front,

single cable, at the park brake lever end.

For servicing information on the ABS Braking System, refer to either Section 5B ABS & ABS/ETC, or

Section 12L ABS & ABS/ETC.

Techline

1.2 MASTER CYLINDER

DESCRIPTION

A master cylinder with a 25.4 mm (1”) diameter bore is used on all VT Series vehicles, regardless of the braking

system fitted. The only difference being that the master cylinder used with ABS has a screw in blanking plug

installed into the lower of the two front brake outlets in the master cy linder.

The master cylinder is a tandem, centre valve design, incorporating a fast fill valve that provides a reduced pedal

travel. The master cylinder is mounted to the vacuum brake booster which in turn, is mounted to the engine side of

the dash panel.

MASTER CYLINDER CONSTRUCTION

This tandem master cylinder arrangement provides separate hydraulic circuits for the application of the brakes, in a

front to rear split arrangement.

Both of these circuits are fed by separate fluid feed and compensating ports, through a common fluid reservoir,

sealed by a diaphragm fitted inside the reservoir cover. This diaphragm provides an effective seal against any

atmospheric moisture coming 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 master cylinder comprise a primary piston with an L type seal and an O-ring seal, a

secondary valve which incorporates a centre valve, a caged spring and two L type seals, a return spring, a

secondary piston stop pin, and a fast fill valve.

In all vehicles, a proportioning valve is located in a parallel bore in the same casting. This valve is used to maintain

the front to rear hydraulic pressure balance and, should one of the two separate systems fail, a separate piston and

differential switch (brake warning lamp switch) are incorporated into the design, so that the vehicle operator can be

warned of a system malfunction.

Figure 5A-1

MASTER CYLINDER OPERATION

The fast fill (fast pressure build up) valve

incorporated into the master cylinder provides

reduced pedal travel by rapidly overcoming the

large low pressure displacements, such as the

advancement of brake pads against the disc with

minimal primary piston travel.

Figure 5A-2

Initial primary piston movement produces pressure

in the larger bore of the master cylinder which

forces closed the flap on the fast fill valve and

prevents fluid from entering the reservoir port.

This high volume low pressure fluid flows over the

primary piston primary L type seal and into the

smaller bore and out to the brake calipers catering

for most of the low pressure brake system

displacement with minimal primary piston travel.

Figure 5A-3

If further prim ary movem ent increas es the pres sure

in the larger bore, and at a pre-determined

pressure, the ball and seat feature incorporated in

the fast fill valve, unloads, preventing additional

pressure rise and allowing fluid to flow from the

larger bore into the reservoir port.

At this point, the small bore section of the master

cylinder functions as a conventional master

cylinder, producing high operating line pressures,

with minimal primary piston travel.

Figure 5A-4

The combination of hydraulic pressure and the

forc e of the prim ary piston acting on the sec ondary

piston spr ing caus es the secondary piston to move

forward.

This action on the secondary piston moving

forward releases the centre valve pin from contact

with the secondary piston stop pin. With the force

of the centre valve spring, and the release of the

centre valve pin, the rubber centre valve seal is

pushed against the front of the secondary piston

inner bore, ef fec tively blocking off the fluid f rom the

rear brake system compensating port.

At the same time, the primary piston L type seal

passes the front brake system compensating port,

closing it off from the reservoir and thus the high

operating fluid pressure is produced.

The high operating fluid pressure influence is then

registered on the proportioning valve, then to the

front and r ear brake c alipers, where the brak es are

applied.

Figure 5A-5

FRONT BRAKE SYSTEM: When the brake pedal

is released and the secondary piston returns, fluid

recuperation will occur from the reservoir through

the replenishing holes in the fast fill valve, over the

rubber flap and into the larger and smaller piston

bores.

When the primary piston has fully returned, the

compensating hole in the master cylinder will be

uncovered, allowing fluid returning from the wheel

cylinders to flow into the reservoir via the fast fill

valve compensating passage, thus relieving all

pressure in the brake system.

Figure 5A-6

REAR BRAKE SYSTEM: When the brake pedal is released and the secondary piston returns, fluid recuperation will

occur from the reservoir and through the centre valve when the centre valve rubber seal becomes unseated from

the secondary piston bore.

Figure 5A-7

Brake fluid pressure is equal in each system until the proportioning valve reaches its designed ‘crack point'. If the

mas ter cylinder pressure then continues to rise, the propor tioning valve operation changes the front to r ear braking

pressures, to maintain the designed front to rear braking balance.

PROPORTIONING VALVE OPERATION

In the relaxed position (see Figure 5A-8), the

proportioning valve piston is held in the valve

housing by the large proportioning spring.

The poppet valve is held against the end of its

retainer by a light return spring and brake fluid is

free to pass from the master cylinder, through the

bore of the proportioning valve piston to the rear

brakes.

Figure 5A-8

W hen master cylinder pressure is increased to the

proportioning valve crack point (see Figure 5A-9),

brake fluid pressur e from the primary section of the

master cylinder acting on the control piston forces

the proportioning valve piston to move to the plug

end, overcom ing the large proportioning s pring and

seals against the poppet valve. This prevents any

further increase in press ure to the rear brakes until

master cylinder pressure is increased.

The proportioning valve piston, once seated, now

has a larger diameter than the control piston. As a

consequence of this differential area, the output to

the rear brakes af ter cr ac k point has been r eac hed,

is less than that applied to the front brakes.

As master cylinder pressure is further increased

above crack point, the piston oscillates against the

poppet valve and proportions the rear brake

pressure to a value lower than the front brakes.

Figure 5A-9

W hen the brake pedal is released (see Figure 5A-

8) and the fluid pressure from the master cylinder

drops, the pressure of the rear brake fluid unseats

the poppet valve, allowing the fluid to return to the

master cylinder. The large proportioning spring

then returns the proportioning valve piston and

control piston to their relaxed positions.

Should a loss of pressure occur in either the front

or rear brake system, when the brake pedal is

applied, the proportioning valve housing will move

within the master cylinder body, closing the switch

contacts on the differential switch and thus

illuminating the brake fail warning light on the

instrument panel.

After repairs have been made, application of a

reasonable force to the brake pedal will

automatically centralise the proportioning valve

housing, opening the differential switch contacts

and turning the brake warning light off.

1.3 FRONT AND REAR BRAKES

Both front and rear brake assemblies are of a revised design for VT Series vehicles but are common for both the

standard and ABS systems. An exploded view of the new twin piston front caliper are shown in Figure 5A-10.

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

within the anchor plate by means of two guide pins bolted to the housing. Rubber boots are fitted to the guide pins

to keep out 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 incorporates either twin (front) or a single hydraulic piston (rear), each with a seal. When hydraulic

pressure is applied, the piston forces the inner pad against the disc and the reaction of the housing 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 2.5 BRAKE PADS, REPLACE, in this Section, for further information regarding brake pad application.

Figure 5A-10

2. MI NOR SERVICE OPERATIONS

2.1 SERVICE NOTES

IMPORTANT ITEMS:

a. While Holden's wheel brake parts are not asbestos based in their material composition, a danger exists that

non-genuine 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.

Even so, 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 protracted period of time.

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.

b. The polyglycol brake fluid used in VT vehicles is hygroscopic and absorbs moisture from the air through the

brake hoses etc. The boiling resistance of the fluid decreases 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 effectiveness, a two yearly change of brake fluid is mandatory, refer to

2.4 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

discarded.

NOTE:

The approved brake fluid (Holden's Specification HN1796) is available in 250 and 500 ml containers. If pressure

bleeding equipment is used, it must be of an approved type with a diaphragm separating the brake fluid from the air.

CAUTION:

Brake fluid is extremely damaging to paint. If fluid should accidentally touch a painted surface, immediately

wash the fluid from the paint and clean the painted surface.

2.2 PARK BRAKE CABLE, ADJUST

1. Raise rear of vehicle and support on jack

stands under each lower control arm, to

maintain the correct suspension attitude.

2. Loosen the park brake cable adjustment 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

(arrow) 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 1:

With a new park brake installation or one that has

the correct park brake shoe adjustm ent, the thread

on the front cable should protrude through the

adjustment nut by 15 - 20 mm.

NOTE 2:

If the park brake cannot be satisfactorily adjusted

by the above method, it will be necessar y to refer to

3.5 PARK BRAKE SHOE, ADJUST in this Section.

Figure 5A-11

2.3 BRAKE SYSTEM BLEED

CAUTION :

Whenever any component that forms part of

the ABS (if fitted) is disturbed during Service

Operations, it is vital that the complete ABS

system be checked, using the procedure as

detailed in DIAGNOSIS, ABS FUNCTION

CHECK, in Section 12L ABS & ABS/ETC.

During overhaul operations, pockets of air may be

trapped in the LHF brake pipe, the front brake

hoses, in the master cylinder and various other

parts of the brake system.

A quick method of locating air pockets is to clamp

the brake hoses near the pipe end. This must be

done using a specially designed clamp that will not

damage the brake hoses. The brake hose clamp,

part number T3, is a suitable clamp obtainable

from PBR - Australia Service Centres.

NOTE:

G-clamps or locking pliers must not be used

under any circumstances.

When approved clamps are used, extreme care

must be taken to ensure they are removed before

the vehicle is driven on the road.

The front chamber of the master cylinder can be

bled by loosening the pipe to the LHF brake at the

master cylinder (2) and allowing brake fluid to drip

from the connection for approximately one minute,

ensuring that spilled fluid drips into a suitable

container. Do not re-use drained fluid and do not

operate the brake pedal or apply pressure to the

master cylinder during this operation.

Remove air from other components of the brake

system as follows:

1. Remove master cylinder reservoir cap (1) and

fit pressure bleed cap, part number 4850-150,

obtainable from Brake and Clutch Industries -

Australia Service Centres.

2. Connect cap to pressure bleed pump and

pressurise system to no more than 345 kPa.

Figure 5A-12

3. Open brake bleeder of line to be bled and

pump brake pedal one stroke/second for

approximately 10 strokes, then close bleeder.

During this operation the pressure bleeder to

the mas ter cylinder should not be tur ned off. It

is essential that this volume and rate of flow is

maintained to ensure air trapped 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.

Figure 5A-13

2.4 BRAKE FLUID, CHANGE

CAUTION :

Whenever any component that forms part of

the ABS (if fitted) is disturbed during Service

Operations, it is vital that the complete ABS

system be checked, using the procedure as

detailed in DIAGNOSIS, ABS FUNCTION

CHECK, in Section 12L ABS & ABS/ETC.

1. Thoroughly clean master cylinder, especially

around wheel brake line connections.

2. Disconnect wheel brake lines from master

cylinder (2) and remove reservoir cap (1).

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 remainder of procedure.

5. Allow fluid to flow from open connection ports

until f luid is free of air . Collect discharged f luid

in suitable container and then discard. Do not

allow fluid to contact paintwork.

Figure 5A-14

6. Reconnect wheel brake lines to master

cylinder and tighten to specified torque.

BRAKE PIPE TO MASTER

CYLINDER FLARE NUT 8 - 11 Nm

TORQUE SPECIFICATION

Drain brake calipers as follows:

7. Raise vehicle and place on safety stands.

Refer to Section 0A GENERAL

INFORMATION for the locations of jacking

and support points.

8. Mark position of wheels relative to hub and

remove wheels.

9. Loosen left hand front caliper bleed screw

(arrow, in Figure 5A-13).

10. Remove front left hand caliper anchor plate

retaining bolts.

NOTE: Dis card the front brak e caliper anchor plate

retaining bolts as they must be replaced on

reassembly.

Figure 5A-15

11. Hold caliper upside down and remove bleed

screw to drain contents of caliper into suitable

receptacle.

12. Hand tighten bleed screw and reinstall caliper

assembly

13. Tighten caliper anchor plate retaining bolts to

specified torque.

FRONT BRAKE

CALIPER ANCHOR 80 – 90 Nm, then

BOLT TORQUE

SPECIFICATION 40° - 50° turn angle

NOTE: Ensure the brake hose plastic sleeve is secured

correctly in suspension strut bracket.

14. Repeat steps 8 to 13 for the remaining caliper

assemblies and tighten the rear brake caliper

anchor plate bolts to the correct torque

specification.

REAR BRAKE CALIPER ANCHOR

BOLT TORQUE SPECIFICATION 70 – 100 Nm

15. Bleed brake system, refer to

2.3 BRAKE SYSTEM BLEED in this section

16. Reinstall road wheel in original position and

lower vehicle.

17. Tighten road wheel nuts to the specified torque

ROAD WHEEL ATTACHING

NUT TORQUE SPECIFICATION 110 – 140 Nm

2.5 BRAKE PADS, REPLACE

CAUTION :

Whenever any component that forms part of

the ABS (if fitted) is disturbed during Service

Operations, it is vital that the complete ABS

system be checked, using the procedure as

detailed in DIAGNOSIS, ABS FUNCTION

CHECK, in Section 12L ABS & ABS/ETC.

This procedure refers to front brake pads. Any

differences relating to rear brake pad replacement

are noted in square brackets.

1. Remove master cylinder reservoir c ap. Loos en

front left (1) [or rear (2)] wheel brake line

connection at m aster cylinder, allowing fluid to

bleed into a container until master cylinder

reservoir is approximately

/3 full. Re tighten

line connection and install master cylinder cap.

NOTE 1:

Do not completely remove the brake line or empty

the reservoir or it will be necessary to bleed the

system.

NOTE 2:

Discard the f luid removed. DO NOT AT TEMPT TO

RE-USE.

NOTE 3:

Removal of fluid from the reservoir is needed to

stop reservoir overflow when caliper piston is

pushed back in its bore during pad replacement.

NOTE 4:

Brake fluid is extremely damaging to paintwork.

Figure 5A-16

2. Raise front (or rear) of vehicle and place on

safety stands. Refer to

Section 0A GENERAL INFORMATION for

the necessary procedures.

3. Mark relationship of wheel to hub. Remove

front (or rear) wheels.

Techline

Important: If the vehicle is fitted with ABS, it is

preferred that a brake pad spreading tool is used

for piston return. However, while G-clamp/s can be

used to return pis tons, they MUST be turned slowly

(e.g. 1/4 turn per second, maximum) to avoid

internal ABS modulator damage.

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

caliper pistons bottoms in each bore.

NOTE:

Ensure that one end of the G-clamp rests on (or is

adjacent to) the brake hose attaching bolt head,

and the other against the outer pad.

Figure 5A-17

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 thread.

6. Swing caliper assembly up from the anchor

plate and disc and support caliper with a wire

hook.

7. Remove worn pads from anchor plate.

8. Inspect condition of brake disc.

9. Check guide pins for fr ee movem ent in anchor

plate. If there is restriction of movement,

replace guide pins and/or guide pin boots.

Refer to 3.3 BRAKE CALIPER in this Section.

10. Clean any dirt f rom both the piston f ace, which

contacts the inner pad, and the caliper head

area which contacts the outer pad.

11. Install new brake pads as follows:

Figure 5A-18

FRONT BRAKE PAD INSTALLATION

1. Thoroughly clean both piston contact faces, using a

suitable solvent such as Prepsol, if required.

2. Peel the backing paper from the inner pad and

install it to the anchor plate, against the brake disc.

NOTE:

Do not handle the exposed, sticky surface of the pad,

particularly in the piston contact areas.

3. Install the outer pad to the caliper, noting that a leg

of the steel spring should sit on top of the inner

pad.

4. Reinstall the brake caliper housing, ensuring that

the outer spring clip engages with the middle finger

of the caliper housing.

5. Install and tighten a NEW guide pin bolt to the

correct torque specification.

GUIDE PIN BOLT 30 - 34

TORQUE SPECIFICATION Nm

NOTE 1:

Use a suitable open end spanner to prevent the guide

pin from rotating when tightening the guide pin bolt.

NOTE 2:

Do not wedge anything between the guide pin hex and

the caliper as it could cause incorrect alignment of the

pin which would subsequently impair the free sliding of

the caliper relative to the anchor plate.

6. Fill master cylinder to correct level with fresh,

specified brake fluid.

7. Depress and hold the brake pedal down in the

applied position for at least 5 seconds, to ensure

that the inner pads stick to the pistons.

8. Refill master cylinder if necessary.

9. Reinstall wheels, aligning marks made prior to

removal and lower vehicle to the ground.

NOTE: Ensure that brake hose plastic sleeve is secured

in suspension strut bracket.

10. Tighten road wheel attaching nuts to the specified

torque.

ROAD WHEEL ATTACHING 110 - 140

NUT TORQUE SPECIFICATION Nm

Techline

REAR BRAKE PAD INSTALLATION

IMPORTANT:

For noise damping effectiveness, it is critical that

the brake pad and shim assemblies are installed in

the correct locations, as detailed here.

1. The outer pad (1) (which is retained by the

fingers of the brake caliper housing), has a full

shim.

2. The inner pad (2) has an asymmetrical or half

shim, that must be correctly installed to the

caliper. The shim must always be on the upper

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

car position).

NOTE:

The brake pads illustrated would therefore, only be

fitted to the left hand side, rear brake caliper, in the

attitude, as shown.

3. Reinstall caliper housing over brake pads.

Ensure spring clip is located correctly in the

top of the caliper body.

4. Install NEW guide pin bolt. Tighten to specified

torque.

GUIDE PIN BOLT 30 - 34

TORQUE SPECIFICATION Nm

NOTE 1:

Use a suitable open end spanner to prevent the

guide pin from rotating when tightening the guide

pin bolt.

NOTE 2:

Do not wedge anything between the guide pin hex

and the caliper as it could cause incorrect

alignment of the pin which would subsequently

impair the free sliding of the caliper relative to the

anchor plate.

5. Fill master cylinder to correct level with fresh,

specified brake fluid.

6. Depress brake pedal several times to bring

pad assemblies into position against disc.

7. Refill master cylinder if necessary.

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.

ROAD WHEEL ATTACHING 110 - 140

NUT TORQUE SPECIFICATION Nm

Figure 5A-19

BRAKE PAD BEDDING-IN PROCEDURE

Whenever brake pads are replaced, they should be burnished, by the following bedding-in procedure:

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 1:

A ‘panic’ stop would be classified as being a 9 g deceleration braking effort, so a ‘moderate’ deceleration rate of 0.4

g would be one that required approximately half the brake pedal effort needed for a ‘panic’ stop.

NOTE 2:

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.

Techline

2.6 BRAKE PEDAL

CAUTION :

Whenever any component that forms part of the ABS (if fitted) is disturbed during

Service Operations, it is vital that the complete ABS system be checked, using the

procedure as detailed in DIAGNOSIS, ABS FUNCTION CHECK, in Section 12L ABS &

ABS/ETC.

CAUTION:

Disable the SRS (Air Bag). Refer to 'DISABLING THE SRS’, Section 12M, SRS.

REMOVE

1. Remove instrument panel lower right trim

assembly. Refer to

Section 1A3, INSTRUMENT PANEL AND

CONSOLE , for details.

2. Remove master cylinder support bracket from

the front of the master cylinder.

Figure 5A-20

3. Remove br ake pipes f rom the mas ter cylinder.

Plug openings in both the master cylinder and

the pipes, to prevent fluid loss and dirt entry.

Figure 5A-21

Campaign

2. Remove nuts (arrow) securing throttle pedal

assembly to dash panel.

3. Remove the remaining two nuts securing the

brake booster to the firewall.

Figure 5A-22

4. Remove push rod retaining clip (1), push rod

(3) and washers (2 and 3) from brake pedal.

5. Remove the three bolts securing the brake

pedal support bracket to the steering column.

6. From the engine compartment, pull the brake

booster forward, allowing the brake pedal and

support to be lowered, rear end first from

under the instrument panel.

Figure 5A-23

7. Remove nut and washer securing pedal shaft

to pedal support.

8. Carefully withdraw shaft from pedal support.

9. Withdraw brake pedal and return spring

assembly.

Figure 5A-24

REINSTALL

1. Lubricate all bearing surfaces with

Molybdenum Disulphide grease (Holden's

Specification HN1271), as indicated in Figure

5A-24.

2. Hold brake pedal and return spring in position

and insert pedal support shaft through pedal

stand.

3. Reinstall shaft retaining washer and nut and

tighten to specified torque.

PEDAL SUPPORT SHAFT NUT 50 - 60

TORQUE SPECIFICATION Nm

4. Reinstall brak e pedal and stand ass embly into

the vehicle and install the three bolts

supporting the pedal stand to the steering

column but do not tighten at this time.

5. Push the brake booster rearward to engage

the four studs with the pedal stand and to

allow the push rod to be installed to the brake

pedal pin.

6. Install the push rod washers and retaining clip

(see Figure 5A-23).

7. Install throttle pedal assembly, install and

tighten all four brake booster nuts to the

specified torque.

BRAKE BOOSTER/THROTTLE

PEDAL BRACKET NUT 20 - 25 Nm

TORQUE SPECIFICATION

8. Tighten the three brake pedal stand bolts to

the specified torque.

BRAKE PEDAL STAND BOLT 20 - 25

TORQUE SPECIFICATION Nm

9. Install the master cylinder support bracket,

tightening the fasteners to the specified

torque.

MASTER CYLINDER BRACKET 15 - 20

NUT TORQUE SPECIFICATION Nm

10. Unplug all hydraulic fitting openings, and

install the brake pipes to the master cylinder,

tightening to the specified torque.

BRAKE PIPE TO MASTER

CYLINDER FLARED NUT 8 - 11 Nm

TORQUE SPECIFICATION

11. Bleed the brake system as detailed in

2.3 BRAKE SYSTEM BLEED, in this Section.

Adjust stop lamp or cruise control switches:

a. Stop Lamp Switch - W ith the pedal held

in the ‘at rest' position, push or pull the

switch (4) through metal clip (3) to

achieve a gap of 6 ± 0.5 mm, as shown,

between brake pedal support (2) and

switch body (4).

Figure 5A-25

b. Cruise Control Switch - Vehicles

equipped with the cruise control feature,

are fitted with two switches. The upper

switch is the cruise control electrical

release switch, while the lower switch (2)

is used to illuminate the stop lamps, and

to provide a signal to the cruise control

module.

With the brake pedal held in the

depressed position, push the switch

forward until the switch body contacts the

tubular clip (1).

Pull the brake pedal fully up against the

brake pedal stop, until audible 'click'

sounds are no longer heard.

Depress the brake pedal again and

repeat the above procedure until the

audible 'click' sounds can no longer be

heard. At this point, the switch will be

correctly adjusted.

8. Reinstall instrument panel lower right trim

assembly.

Figure 5A-26

2.7 PARK BRAKE LEVER

REMOVE

1. Set park brake in the fully released position.

2. Slip the park brake lever boot to one side, then

remove the park brake front cable adjusting

nut (arrow), using a deep socket.

3. Remove driver’s seat. Refer

Section 1A7 SEAT & SEAT BELT

ASSEMBLIES.

4. Lift the carpet from around the park brake

lever, then remove the two mounting bolts.

5. Carefully lift park brake lever assembly,

upwards to free the cable, then disconnect

electrical connector (‘5’ in Figure 5A-28) from

park brake switch.

6. Remove the lever assembly from the vehicle.

Figure 5A-27

REINSTALL

Installation is the reverse of the r emoval proc edure,

except for the following:

1. Tighten park brake lever bolts to specified

torque.

PARK BRAKE LEVER BOLT 35 -65

TORQUE SPECIFICATION Nm

2. Reinstall threaded end of the front park brake

cable, then install the adjusting and lock nut.

Adjust the park brake cable adjustment as

detailed in 2.2 PARK BRAKE CABLE,

ADJUST in this Section.

2.8 FRONT PARK BRAKE CABLE

REMOVE

1. Set park brake in the fully released position.

2. Remove driver’s seat. Refer

Section 1A7 SEAT & SEAT BELT

ASSEMBLIES for the procedure.

3. Remove the park brake lever as detailed in 2.7

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. Remove the two

screws.

Figure 5A-28

5. Raise vehicle and place safety stands under

each of the rear trailing arms. Refer to

Section 0A, GENERAL INFORMATION for

the recommended support points for the

vehicle front.

6. Pull each park brake rear cable forward and

up (1) to release it from the equaliser bracket.

Pull to the rear (2) to remove the cable from

the retaining bracket.

7. Remove the front cable outer cable retaining

bracket bolt (‘4’ in Figure 5A-28) from the

vehicle underbody.

NOTE:

Depending on the engine/transm ission fitted to the

vehicle, it may be necessary to first remove the

propeller shaft to enable access to this bolt. Refer

to Section 4C PROPELLER SHAFT AND

UNIVERSAL JOINTS for the procedure.

Figure 5A-29

8. Manoeuvre the front cable assembly and

equaliser bracket, through the aperture in the

floor pan, removing the cable assembly from

inside the vehicle.

REINSTALL

Installation is the reverse to the removal procedure.

1. Manoeuvre the front cable and escutcheon

plate assembly, through the hole in the floor

pan, ensuring that the rubber seal is correctly

positioned. Install the two self tapping screws,

securing the plate to the floor pan.

2. Install the park brak e lever and tighten bolts to

the specified torque.

PARK BRAKE LEVER BOLT 35 -65

TORQUE SPECIFICATION Nm

3. Install the park brake front cable adjusting nut

a few threads to secure the cable.

4. Install the outer front cable retaining bracket

bolt to the vehicle underbody, tightening to the

correct torque specification.

OUTER FRONT CABLE BRACKET 6 - 14

BOLT TORQUE SPECIFICATION Nm

5. As required, install the propeller shaft. Refer to

Section 4C PROPELLER SHAFT AND

UNIVERSAL JOINTS for the procedure and

the specified torque specifications.

6. Reinstall the driver’s seat and centre console.

7. Reinstall the two rear cables to the equaliser

bracket.

8. Adjust the park brake, as detailed in

2.2 PARK BRAKE CABLE, ADJUST in this

Section.

9. Lower the vehicle to the ground.

2.9 REAR PARK BRAKE CABLE/S

REMOVE

1. Release park brake.

2. Using a deep socket, loosen the front cable

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-30

4. To provide sufficient access, it may be

necessary to remove the propeller shaft from

the vehicle. Refer to

Section 4C PROPELLER SHAFT AND

UNIVERSAL JOINTS for the necessary

procedures.

5. Unclip each (or as required) of the cable

grommets from the underbody clip/s, to free

the cable/s.

Figure 5A-31

6. Rem ove the front of the rear cable/s by pulling

the ball nipple forward and up (1), to f ree from

the equaliser bracket.

7. Free the front end of the outer cable from the

underbody bracket by pulling the outer cable

rearward (2).

Figure 5A-32

7. Disconnect the rear clevis from the rear park

brake actuating lever by gripping with pliers

and pivoting the cable rearwards.

8. Pull outer cable forward, out of trailing arm

retainers and remove the cable/s from the

vehicle.

Figure 5A-33

REINSTALL

Installation of the rear park brake cable/s is the

reverse of removal procedure, except for the

following points:

1. Install the cable through the trailing arm

retainer, then fit the cable clevis to the park

brake actuating lever.

2. Wrap rag around the inner cable to protect it

from damage, then use pliers to pull the ball

end on the inner cable forward to engage into

the equaliser bracket.

3. Reinstall the propeller shaft. Ref er to Section

4C PROPELLER SHAFT AND UNIVERSAL

JOINTS for all details.

4. Adjust park brake cable, refer

2.2 PARK BRAKE CABLE, ADJUST, in this

Section.

2.10 FRONT BRAKE HOSE

CAUTION :

Whenever any component that forms part of the ABS (if fitted) is disturbed during

Service Operations, it is vital that the complete ABS system be checked, using the

procedure as detailed in DIAGNOSIS, ABS FUNCTION CHECK, in Section 12L ABS &

ABS/ETC.

REMOVE

1. Raise front of vehicle and place on jack stands.

Refer to Section 0A GENERAL INFORMATION

for the recommended procedure.

2. Mark position of wheel relative to hub and

remove road wheel.

3. Thoroughly clean connections at each end of

brake hose.

4. Disconnect brake pipe from hose and plug pipe.

5. Remove the self-tapping screw (1) securing the

hose bracket to the inner skirt panel.

6. Remove the brake hose from the suspension

strut bracket by turning plastic sleeve on the

hose until the flats on the sleeve align with

brack et opening. Unc lip hose and sleeve ( 2) fr om

bracket.

7. Unbolt and remove brake hose from caliper.

Figure 5A-34

Techline

REINSTALL

1. Ensure brake hose and caliper mating surfaces are

clean and free from burrs.

2. Reconnect brake hose (1) to caliper and tighten

bolt (2) to specified torque.

BRAKE HOSE TO CALIPER 32 - 37

TORQUE SPECIFICATION Nm

NOTE:

Use NEW copper washers (3).

3. Install the brake hose to the strut bracket by turning

plastic sleeve on the hose until the flats on the

sleeve align with the bracket opening. Clip hose

and sleeve into suspension strut bracket and

secure the sleeve to the bracket by rotating 90º.

4. Reinstall the self tapping screw to retain the hose

bracket to the inner skirt panel.

5. Remove plug from brake pipe and reconnect to

hose. Tighten to specified torque.

BRAKE PIPE TO BRAKE

HOSE FLARED NUT 14 - 17 Nm

TORQUE SPECIFICATION

6. Check that hose is not twisted.

7. Bleed brake/s, see 2.3 BRAKE SYSTEM BLEED,

in this Section.

8. Reinstall road wheel, aligning marks made on

removal and lower vehicle.

Figure 5A-35

9. Tighten road wheel attaching nuts to the specified

torque.

ROAD WHEEL ATTACHING 110 - 140

NUTS TORQUE SPECIFICATION Nm

2.11 REAR CALIPER BRAKE HOSE

CAUTION:

Whenever any component that forms part of the ABS (if fitted) is disturbed during

Service Operations, it is vital that the complete ABS system be checked, using the

procedure as detailed in DIAGNOSIS, ABS FUNCTION CHECK, in Section 12L ABS &

ABS/ETC.

REMOVE

1. Raise rear of vehicle and place on jack stands.

Refer to Section 0A GENERAL

INFORMATION for the procedure.

2. Mark position of wheel relative to hub and

remove road wheel.

3. Thoroughly clean connections at each end of

brake hose.

4. While holding the hose (2) with a back-up

spanner, loosen then disconnect brake pipe

from brake hose. Plug the pipe open end.

5. Unclip retainer (1) from hose and withdraw

hose from bracket.

6. Unbolt and remove brake hose from caliper.

Figure 5A-36

REINSTALL

1. Ensure brake hose and caliper mating

surfaces are clean and free of burrs.

2. Reconnect brake hose to caliper and tighten

bolt to specified torque.

BRAKE HOSE TO CALIPER 32 - 37

BOLT TORQUE SPECIFICATION Nm

NOTE:

Use new copper washers and ensure peg on hose

aligns with dimple in caliper.

3. Fit hose correctly into mounting plate bracket

and reinstall retainer. Check that hose is not

twisted.

4. Remove plug from brake pipe and reconnect

to hose. While using a back -up spanner on

the brake hose to prevent twisting, tighten pipe

to specified torque.

BRAKE PIPE TO HOSE FLARED 14 -17

NUT TORQUE SPECIFICATION Nm

5. Bleed brake/s, see 2.3 BRAKE SYSTEM

BLEED, in this Section.

6. Align marks made prior to removal, then

reinstall the road wheel. Lower vehicle.

7. Tighten road wheel attaching nuts to the

specified torque.

ROAD WHEEL ATTACHING 110 - 140

NUT TORQUE SPECIFICATION Nm

2.12 RE AR BRAKE HOSE

CAUTION :

Whenever any component that forms part of the ABS (if fitted) is disturbed during

Service Operations, it is vital that the complete ABS system be checked, using the

procedure as detailed in DIAGNOSIS, ABS FUNCTION CHECK, in Section 12L ABS &

ABS/ETC.

REMOVE

1. Raise rear of vehicle and place on jack

stands. Refer to Section 0A GENERAL

INFORMATION, for details.

2. Thoroughly clean connections at each end of

the rear brake hose to be removed.

Figure 5A-37

3. Disconnect brake pipe from brake hose at

trailing arm brackets (View [B]). Plug open end

of brake pipe/s to prevent foreign material entry.

4. Disconnect brake hose connection pipe from

brake hose, while holding the hose with a back -

up spanner. For thos e vehicles without ET C, the

RH side brake hose (View [C]), also has a

junction block to provide for a connection from

the master cylinder. Plug all pipe ends to

prevent foreign material entry.

5. Unclip retainers from the end of each hose end

and withdraw hose from brackets.

Figure 7C5-38

REINSTALL

1. Ensure brake hose ends and pipe mating

surfaces are clean and free of burrs.

2. Fit hose into mounting plate brackets and

reinstall retainers. Check that hose is not

twisted.

3. Remove plugs from brake pipes and

reconnect to hose ends. Tighten all pipe nuts

to specified torque.

BRAKE PIPE FLARE NUT

TO BRAKE HOSE TORQUE 14 - 17 Nm

TORQUE SPECIFICATION

4. Bleed brake/s, see 2.3 BRAKE SYSTEM

BLEED, in this Section.

5. Raise vehicle, remove jack stands, then lower

vehicle to the ground.

3. MAJOR SERVICE OPERATIONS

CAUTION :

Whenever any component that forms part of the ABS (if fitted) is disturbed during

Service Operations, it is vital that the complete ABS system be checked, using the

procedure as detailed in DIAGNOSIS, ABS FUNCTION CHECK, in Section 12L ABS &

ABS/ETC.

3.1 MASTER CYLINDER

REMOVE

1. Remove master cylinder reservoir cap

temporarily and syphon brake fluid from the

reservoir. Reinsta ll reservoir cap.

2. Disconnect electrical connector from brake

warning, differential switch.

3. Disconnect brak e lines f rom m as ter cylinder and

plug both the lines and master cylinder

apertures, to prevent dirt ingress.

Figure 5A-39

4. Remove bracket securing master cylinder to

adjacent spring tower.

5. Remove nuts securing master cylinder to brake

booster and remove master cylinder.

IMPORTANT:

DO NOT disturb brake booster push rod and DO

NOT depress brake pedal with master cylinder

removed or the internal reaction disc in the booster

may become dislodged.

Figure 5A-40

DISASSEMBLE

1. Clean the outside of the master cylinder.

2. Remove reservoir cap and seal. Discard any

fluid left in reservoir

3. Unscrew the reservoir to body retaining screw,

located at the base of the reservoir.

4. Separate the plastic r eservoir, by hand, fr om the

body.

5. Remove the two reservoir sealing grommets

from the body.

Figure 5A-38

6. Invert master cylinder body so that the reservoir

ports face downwards. Depress the primary

piston with a wood dowel or brass rod until the

piston bottoms in the bore of the m ast er cylinder

body. The secondary piston stop pin should

freely fall out.

7. Carefully remove primary piston from the main

bore of the master cylinder.

Figure 5A-42

8. Remove secondary piston and return spring by

lightly tapping the open end of the master

cylinder bore squarely onto a soft piece of wood.

NOTE 1:

The caged spring of the secondary piston has been

set to a predetermined length. Do not attempt to

adjust or remove the caged spring.

NOTE 2:

The centre valve is part of the secondary piston

assembly and is not serviced as a separate part.

Figure 5A-43

9. Remove the seal retainer from the primary

piston by using a small screwdriver to carefully

pry apart the seal retainer legs.

10. Remove the recuperating guide and seal from

the primary piston.

11. Remove all rubber seals from both pistons,

taking EXTREME CARE not to damage the

pistons.

Figure 5A-44

12. Using suitable circlip pliers, remove the circlip

retaining the fast fill valve located in the primary

reservoir port of the master cylinder.

13. Face the master cylinder reservoir ports

downwards to allow the fast fill valve to fall out. If

the valve is stuck, lightly tap the master cylinder

on a piece of wood to assist removal.

14. Remove the valve sealing O-ring from the

bottom of the reservoir port.

Figure 5A-45

15. Unscrew and remove the end plug from the

master cylinder body.

16. Remove the differential switch from the master

cylinder, ensuring that the electrical earthing

spring remains on the switch plunger.

17. Remove the proportioning valve assembly by

lightly tapping the 'end plug' end of the cylinder

bore squarely onto a soft piece of wood to

dislodge the proportioning valve assembly.

IMPORTANT:

Do not damage the proportioning valve assembly by

attempting to pull it out of the bore with pliers.

NOTE:

Do not disassemble the proportioning valve assembly

as this valve is only serviced as a complete

assembly.

Figure 5A-46

CLEAN AND INSPECT

NOTE:

Ensure work area is c lean and f ree of dust or other

contam inants . T hes e c an af f ec t the per f ormanc e of

all the seals in the master cylinder.

1. W ash m aster cylinder body, reservoir and c ap

in clean methylated spirits.

2. Wash all internal parts in brake fluid.

3. Check all recesses, openings and passages

to ensure they are open and free of foreign

matter.

4. Place all parts on a clean surface.

5. Inspect the master cylinder bores for signs of

etching, pitting, scoring or rust. If in poor

condition, replace the master cylinder.

IMPORTANT:

Do not hone the master cylinder bor e.

6. Discard all rubber parts together with the

secondary piston assembly (the secondary

piston assembly incorporates; the secondary

piston, the centre valve and the caged s pring).

Only new parts from the genuine service kit

should be used to reassemble the master

cylinder.

REASSEMBLE

NOTE 1:

Before assembly, lubricate internal parts and

master cylinder bores with clean, recommended

brake fluid from a sealed container.

NOTE 2:

Prior to assembly, ensure that the primary piston,

without seals fitted to it, is free to move the full

piston stroke in the large bore.

Figure 5A-47

1. Install O-r ing seal into the groove at the end of

the primary piston.

2. Install the recuperating guide followed by the

primary L type seal onto the end of the primary

piston. The sealing face of the L type seal

must face away from the recuperating guide.

NOTE:

The primary L type seal for the primary piston can

be identified by the six shallow grooves around the

seals outer surface.

3. Assemble the seal retainer onto the primary

piston. Using a small screwdriver, clip the

retaining legs of the retainer into the groove on

the primary piston. Care should be taken to

avoid damage to the piston or seal. Figure 5A-48

4. Assemble the small end of the return spring

over the end of the secondary piston. This

should be a slight interference fit.

Figure 5A-49

5. Carefully insert the secondary piston, caged

spring end last, through the lar ge bor e and into

the smaller bore of the master cylinder until the

return spring 'bottoms'. Ensure the secondary

spring does not dislodge from the piston

assembly during this operation.

NOTE:

To assemble the secondary piston assembly into

the body, align the slot in the sec ondary piston with

the hole in the reservoir ports. This must be done

so that the secondary piston stop pin can be

inserted into secondary reservoir port in the m aster

cylinder.

Fully stroke the secondary piston using a soft

dowel and while held at the bottom of the bor e,

install the secondary piston stop pin into the

secondary reservoir port. The piston stop pin

should easily fit through the larger hole of the

two holes located in the secondary reservoir

port. The top of the secondary piston stop pin

should not protrude more than 6 mm above

the bottom of the reservoir port.

Figure 5A-50

6. Insert the primary piston into the main bore,

against the secondar y piston and caged s pring

assembly. Carefully push both pistons down

the bore until the primary piston is flush with

the bore opening.

7. Stroke pistons and check that the primary

piston returns to the end of the bore af ter each

stroke. Ensure movement is not sticky.

Figure 5A-51

8. Fit new O-rings onto proportioning valve.

9. Ensure spacer and O-ring are fitted over the

proportioning valve spool and that they are

installed the right way (spacer first followed by

the O-ring).

10. Insert proportioning valve into the bore,

capped end first. Extreme care should be

taken when inserting the valve to ensure that

the O-rings are not damaged. If O-rings are

damaged, the master cylinder will not function

correctly and will leak brake fluid. The

proportioning valve assembly must be

bottomed in the bore of the master cylinder.

11. As sem ble a new O-ring onto the end plug, and

screw the end plug into the master cylinder

body.

END PLUG 25 - 30

TORQUE SPECIFICATION Nm

Figure 5A-52

12. Reinstall differential switch and spring. Do not

over tighten.

NOTE:

Ensure the earthing spr ing on the differential s witch

is installed on the plunger as shown. If necessary,

the small end of the spring may need to be closed

down slightly to give the required attachment.

DIFFERENTIAL SWITCH 2

TORQUE SPECIFICATION Nm

Figure 5A-53

13. Carefully install the fast fill valve O-ring in the

bottom shoulder of the primary reservoir port.

14. Fit the fast fill valve into the primary reservoir

port, ensuring the rubber base with six dim ples

is faced downwards. Secure valve with circlip.

Figure 5A-54

15. Lightly smear the bores of the reservoir ports

and sealing grommets with clean brake fluid.

16. Carefully assemble sealing grommets into the

bores of the reservoir ports to locate them

against the shoulder in each bore.

17. Reinstall reservoir by pushing reservoir into the

sealing grommets until the hole for the

retaining screw in the reservoir aligns with the

master cylinder body. Install retaining screw

and tighten to the specified torque. The

retaining screw should just protrude from the

hole in the master cylinder body when

tightened.

NOTE:

Both reservoir and master cylinder holes must be

aligned when installing the res ervoir r etaining scr ew

to avoid cross threading.

RESERVOIR SCREW 4.0 - 5.0

TORQUE SPECIFICATION Nm

18. Fill the master cylinder with fresh,

recommended brake fluid and bleed on the

bench prior to replacing on the vehicle. After

bleeding, block master cylinder outlet ports to

prevent fluid escaping.

19. Assemble new reservoir seal into reservoir

cap. Lubricate inside of the reservoir lips with

clean brake fluid to accept the reservoir cap

seal.

20. Reinstall cap seal and cap.

Figure 5A-55

REINSTALL

1. Reinstall master cylinder assembly on brake

booster taking care not to disturb brake

booster push rod. Tighten master cylinder nuts

to specified torque.

MASTER CYLINDER ATTACHING 15 - 20

NUT TORQUE SPECIFICATION Nm

2. Reinstall bracket securing master cylinder to

adjacent spring tower. Tighten nuts and bolt to

specified torque.

MASTER CYLINDER BRACKET 15 - 20

NUT TORQUE SPECIFICATION Nm

3. Unplug brake lines and master cylinder outlet

ports, reinstall pipes to master cylinder and

tighten to specified torque.

BRAKE PIPE TO MASTER

CYLINDER FLARED NUT 8 - 11 Nm

TORQUE SPECIFICATION

4. Reconnect electrical connector to differential

switch.

5. Bleed brake system, refer to 2.2 PARK

BRAKE CABLE, ADJUST in this Section. Figure 5A-56

3.2 BRAKE BOOSTER

CAUTION :

Whenever any component that forms part of

the ABS (if fitted) is disturbed during Service

Operations, it is vital that the complete ABS

system be checked, using the procedure as

detailed in DIAGNOSIS, ABS FUNCTION

CHECK, in Section 12L ABS & ABS/ETC.

NOTE:

The brake booster is not a serviceable item and if

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

REMOVE

1. Remove master cylinder, refer to

3.1 MASTER CYLINDER in this Section.

IMPORTANT:

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.

2. Remove vacuum hose from brake booster

body. While the V6 engine application is

shown in Figure 5A-57, the V6 supercharged

and V8 attachment methods are similar.

Figure 5A-57

3. Remove instrument panel lower right trim

assembly. Refer to

Section 1A3 INSTRUMENT PANEL AND

CONSOLE, for details.

4. Remove push rod retaining clip (1), push rod

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

Figure 5A-58

5. Remove brake booster assembly retaining

nuts (4 places) at brake pedal support, from

inside vehicle.

6. Withdraw booster from engine compartment,

turning booster towards engine to clear spring

tower.

Figure 5A-59

REINSTALL

Installation is the reverse of the r emoval proc edure,

except for the following:

1. Lubricate brake pedal and push rod

component bearing surfaces with

Molybdenum Disulphide grease (Holden's

Specification HN1271), refer to

Figure 5A-58.

2. Ensure brak e boos ter hose is routed c orrec tly,

refer Figure 5A-57, for V6 engines.

3. Reinstall master cylinder as detailed in

3.1, MASTER CYLINDER, in this Section.

4. Tighten brake booster retaining nuts to

specified torque.

BRAKE BOOSTER RETAINING 20 - 25

NUT TORQUE SPECIFICATION Nm

3.3 BRAKE CALIPER (FRONT & REAR)

CAUTION :

Whenever any component that forms part of the ABS (if fitted) is disturbed during

Service Operations, it is vital that the complete ABS system be checked, using the

procedure as detailed in DIAGNOSIS, ABS FUNCTION CHECK, in Section 12L ABS &

ABS/ETC.

REMOVE

. Raise vehicle and place on jack stands.

2. Mark position of road wheel relative to hub

and remove wheel.

3. Place a drain tray beneath caliper assembly.

4. Loosen and remove brake hose to caliper

attaching bolt. Separate bolt from hose and

discard sealing washers.

5. Remove anchor plate retaining bolts and lift

caliper assembly out over disc.

NOTE: Dis card the front brak e caliper anchor plate

retaining bolts as they must be replaced on

reassembly.

Figure

6. The removal procedure for the rear brake

caliper is similar to that for the front.

Figure 5A-61

Techline

DISASSEMBLE

Figure 5A-62

Figure 5A-63

1. Remove guide pin bolts and discard.

2. Separate caliper housing from anchor plate

and remove brake pads.

3. Withdraw guide pins and boots from anchor

plate. Separate boots from pins.

4. Pack a clean piece of cloth between caliper

piston/s and opposite legs on housing and

apply air pressure at brake hose inlet port to

eject a piston.

CAUTION:

Apply light air pressure initially and

progressively increase until the pist on is fo rced

out of the bore. This precaution is advisable to

avoid physical injury, as the piston may

develop considerable force due to the air

pressure.

NOTE:

As only one piston in the front caliper will be

rem oved by this m ethod, r emoval of the s ec ond will

need to be done by us ing internal expanding circlip

pliers, to grasp the inner piston wall. Then, while

twisting the piston, apply a pulling force at the same

time to remove the piston from its bore.

5. Remove rubber boot from bore.

6. Remove seal from bore, taking care not to

damage bore or seal locating groove.

7. Remove bleeder screw.

Figure 5A-64

CLEAN AND INSPECT

1. Clean all metal parts thoroughly with

methylated spirits. Clean rubber parts with

brake fluid only. Use clean, dry compressed

air to dry parts.

2. Examine bore and piston carefully for signs of

damage, abrasion, scuffing or corrosion.

RENEW PISTON IF ANY OF THESE

FACTORS EXIST OR IF THERE IS ANY

DOUBT REGARDING ITS CONDIT ION. If the

bore is unser viceable, a new housing m ust be

fitted.

3. Inspect guide pins f or corrosion. Replace pins

if corroded.

4. Blow through bleed screw port with

compressed air.

REASSEMBLE

1. Lubricate cylinder bore and piston with

specified brake fluid (Holden's Specification

HN1796).

2. Fit new seal into inner groove of bore. Ensure

seal is not twisted and is fully seated in

groove.

3. Install piston boot (1) over end of piston (2).

Figure 5A-65

4. Position each piston (2) into caliper housing

(4), seating boot (1) into groove in caliper

bore. Ensure boot flange is s quarely and firm ly

seated in groove.

5. Push piston squarely into bore by hand until

fully seated. Ensure piston boot is fully seated

in piston and caliper bore grooves.

6. Lubricate guide pins with silicone type grease

(Dow Corning No. 44, Holden's part number

VS16477).

Figure 5A-66

7. Reinstall guide pins (1) in caliper housing (4)

using NEW caliper housing to guide pin bolts

(3). Use an open end spanner to hold flat

section of guide pin when tightening bolts to

correct torque.

GUIDE PIN BOLT 30 - 34

TORQUE SPECIFICATION Nm

NOTE:

Do not re-use old bolts.

8. Install new guide pin boots (2).

9. Assemble caliper hous ing (4) and anc hor plate

(5) together. Ensure guide pin boots are

correctly located in guide pin and anchor plate

grooves.

10. Reinstall bleed screw.

11. Reinstall brake pads, refer to

2.5 BRAKE PADS, REPLACE in this Section,

for correct installation procedure.

Figure 5A-67

REINSTALL

1. Ensure anchor plate mounting surfaces are

clean.

2. Press inner brake pad by hand to ensure

piston is bottomed in bore.

3. Position caliper assembly over disc, insert

anchor plate retaining bolts. Tighten bolts to

specified torque, refer Figures 5A-60 and

5A-61.

NOTE: New retaining bolts must be used when

reinstalling the front brake caliper anchor plate.

FRONT BRAKE CALIPER 80- 90 Nm, plus

ANCHOR PLATE BOLT 40 - 50

TORQUE SPECIFICATION turn angle

REAR BRAKE CALIPER

ANCHOR PLATE BOLT 70 - 100 Nm

TORQUE SPECIFICATION

4. Reconnect brake hose (1) using NEW, dry,

sealing washers (3). Tighten attaching bolt (2)

to the correct torque specification.

BRAKE HOSE TO CALIPER 32 - 37

BOLT TORQUE SPECIFICATION Nm

5. Bleed brake system, refer to 2.3 BRAKE

SYSTEM, BLEED, in this Section.

6. Depress brake pedal several times to bring

pads into position against disc.

7. Reinstall road wheel(s), aligning marks made

prior to removal, then lower vehicle.

NOTE: Ensure that brake hose plastic sleeve is

secured correctly in suspension strut bracket.

8. Tighten road wheel attaching nuts to the

specified torque.

ROAD WHEEL ATTACHING NUT 100 - 125

TORQUE SPECIFICATION Nm

9. Check level of fluid in master cylinder.

Figure 5A-68

3.4 BRAKE DISC (FRONT AND REAR)

CAUTION :

Whenever any component that forms part of the ABS (if fitted) is disturbed during

Service Operations, it is vital that the complete ABS system be checked, using the

procedure as detailed in DIAGNOSIS, ABS FUNCTION CHECK, in Section 12L ABS &

ABS/ETC.

REMOVE

Remove brake caliper assembly, refer to

3.3 BRAKE CALIPER (FRONT AND REAR), in

this Section.

NOTE:

It is not necessary to disconnect brake hose from

caliper. Support caliper with wire hook to avoid

strain on brake hose.

Front Brake

IMPORTANT:

The brake disc to hub relationship is carefully

matched during production, to minimise the effect

of a tolerance stack-up, that could result in disc

runout and subsequent brake shudder.

Therefore, prior to removal of the front disc/s,

check to see whether a paint daub mark is still

visible on the disc hub surface, adjacent to one of

the wheel studs and in alignment with the two

marks on the end of the hub, as shown.

If the paint marks are no longer visible, then

carefully mark the relationship of the disc to the hub

for installation. If this precaution is not taken, then a

disc runout condition could be induced that will

cause brake shudder. Figure 5A-69

If necessary, jar the disc loose by carefully tapping

the disc in the centre between the wheel studs, with

a soft faced hammer, taking care not to damage

the wheel stud threads.

Rear Brake

Ensure park brake is fully released then withdraw

disc f r om wheel studs. As with the fr ont disc , it may

be necessary to jar the disc to loosen, first.

In addition, park brake shoe adjustment may need

to be loosened, to allow the disc to be removed

over the park brake shoes. Refer to Operation

3.5 PARK BRAKE SHOE, ADJUST , in this Section

for details.

Techline

FRONT DISC, INSPECT

If disc surface is rusted or lightly scored, resurf ace

disc. Scores less than 0.4 mm deep will not affect

brake performance.

If scoring is deep or if disc parameters are out of

specification, the disc must be machined.

NOTE 1:

Machine or resurface BOTH sides of disc. Do not

machine or resurface one side only.

NOTE 2:

After machining, disc should be ground to achieve

a non-circumferential finish of 0.4 to 2.0 microns.

Figure 5A-70

NOTE 3:

After machining, the brake disc outer diameter

cham fer m ust be 45° x 1 mm max imum with a pad

to chamfer clearance of 1.3 mm minimum to 2.5

mm maximum. This is to prevent thermal stress

cracking at the top of the disc.

Figure 5A-71

NOTE 4:

Replace disc if specifications cannot be achieved

above the minimum disc thickness.

WARNING:

THE NUMBER CAST INTO THE HUB IS THE

MINIMUM SAFE THICKNESS. AT THIS

THICKNESS THE DISC MUST BE REPLACED

Figure 5A-72

Inspect disc as follows:

1. Check that lateral run-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°.

Figure 5A-73

2. Check that both surfaces are flat within 0.05

mm TIR.

Figure 5A-74

3. Check that disc surfaces are parallel with each

other to within 0.08 mm, when checked

radially.

Figure 5A-75

4. Check that total circumferential thickness

variation, at any radius, does not exceed 0.013

mm in 360° as disc is rotated.

Figure 5A-76

REAR DISC, INSPECT

If disc surface is rusted or lightly scored, resurface

disc. Scores less than 0.4 mm deep will not affect

brake performance.

If scoring is deep or if disc parameters are out of

specification, the disc must be machined.

NOTE 1:

Machine or resurface BOTH sides of disc. Do not

machine or resurface one side only.

NOTE 2:

After machining, disc finish should be 0.6 to 1.25

microns and should not be circumferential i.e. disc

finish s hould be non-direc tional. Park brak e surf ace

finish should be 20 microns.

NOTE 3:

Replace disc if specifications cannot be achieved

above the minimum disc thickness.

WARNING:

THE MINIMUM SAFE THICKNESS IS 13.9 mm.

THE DISC MUST BE REPLACED AT THIS

THICKNESS!

Inspect disc as follows:

1. Check that surface ‘B' is flat within 0.08 mm

and is parallel with surface ‘A' within 0.08 mm

Total Indicated Runout (TIR).

2. 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

3. Check that each disc surf ace is flat within 0.05

mm and is parallel to surface ‘A' within 0.085

mm TIR

4. Check that lateral run-out of each braking

surface 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 not

exceed 0.03 mm in 30°.

5. Check that thickness does not vary by more

than 0.013 mm at any radius when disc is

rotated.

Figure 5A-77

REINSTALL

1. Reinstall disc over wheel studs.

2. Ensure anchor plate mounting surfaces are

clean.

3. Position caliper assembly over disc, insert

anchor plate retaining bolts and washers.

4. Ensure brake hose is not kinked or twisted.

5. Tighten anchor plate bolts to specified torque.

FRONT BRAKE CALIPER 80- 90 Nm, plus

ANCHOR PLATE BOLT 40° - 50°

TORQUE SPECIFICATION turn angle

REAR BRAKE CALIPER

ANCHOR PLATE BOLT 70 - 100 Nm

TORQUE SPECIFICATION

6. Depress brake pedal several times to bring

pads into position against disc.

7. Adjust park brake shoe clearance as detailed

in 3.5 PARK BRAKE SHOE, ADJUST, in this

Section.

8. Reinstall road wheels aligning marks made

prior to removal, then lower vehicle.

9. Tighten road wheel attaching nuts to the

specified torque.

ROAD WHEEL ATTACHING NUT 110 - 140

TORQUE SPECIFICATION Nm

3.5 PARK BRAKE SHOE, ADJUST

CAUTION:

Whenever any component that forms part of

the ABS (if fitted) is disturbed during Service

Operations, it is vital that the complete ABS

system be checked, using the procedure as

detailed in DIAGNOSIS, ABS FUNCTION

CHECK, in Section 12L ABS & ABS/ETC.

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

centre caps (alloy wheels).

3. Mark relationship of wheels to mounting

flanges.

4. Remove road wheel attaching nuts and

remove wheels.

5. Release park brake and ensure that park

brake actuator arms have fully retracted.

If neces sary, loosen the front park br ake cable

adjustment nut (arrow) with a deep socket, to

ensure slack in the park brake rear cables.

Figure 5A-78

Method 1

6. Remove the access hole plug. 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 pr ovided in the

disc.

7. Loosen the adjuster 3 - 5 clicks, then check

that the disc is free and does not drag.

Replace the access hole plug when the

adjustment procedure has been completed.

Figure 5A-79

Method 2

8. Remove rear brake caliper anchor plate to

trailing arm attaching bolts (both sides of

vehicle), then remove calipers from discs.

Using wire, tie up calipers to lower end of

shock absorber upper mountings. DO NOT

ALLOW CALIPERS TO HANG BY BRAKE

HOSES!

Figure 5A-80

9. Remove disc from rear trunnion, then adjust

each park brake shoe to 189.3 - 189.6 mm

diameter across the linings, using the screw

adjuster provided.

NOTE:

The trunnion has been omitted from the illustration

for clarity.

10. Reinstall rear brake discs and check that they

rotate freely and do not bind.

Figure 5A-81

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 70 - 100 Nm

BOLT TORQUE SPECIFICATION

12. Reinstall rear wheels, aligning marks made

prior to removal, and install attaching nuts.

13. Check park brake cable adjustment, refer to

2.2 PARK BRAKE CABLE, ADJUST, in this

Section.

14. Remove safety stands and lower vehicle.

15. Tighten road wheel attaching nuts to the

correct torque specification.

ROAD WHEEL ATTACHING NUT 110 - 140

TORQUE SPECIFICATION Nm

16. Refit wheel covers/centre caps.

3.6 PARK BRAKE SHOE

CAUTION:

Whenever any component that forms part of the ABS (if fitted) is disturbed during

Service Operations, it is vital that the complete ABS system be checked, using the

procedure as detailed in DIAGNOSIS, ABS FUNCTION CHECK, in Section 12L ABS &

ABS/ETC.

REMOVE

1. Using a floor jack under centre of rear axle,

jack up and support rear of vehicle on jack

stands under rear trailing arms (rear axle

housing).

2. Remove rear wheel covers on steel wheels or

centre caps on alloy wheels.

3. Mark relationship of wheels to mounting

flanges. Remove road wheel attaching nuts

and remove wheels.

4. Release park brake.

5. Remove brake caliper anchor plate to trailing

arm attaching bolts and remove calipers from

disc.

Using wire, tie up calipers to lower end of

shock absorber upper mountings. DO NOT

ALLOW CALIPERS TO HANG BY BRAKE

HOSES.

6. Remove brake discs.

NOTE:

It may be necess ar y to loosen the park br ake shoe

adjustment, to enable disc removal. Use a suitable

size screwdriver, screw in adjuster, using one of

the two access holes in the brake disc (see Figure

5A-79).

Figure 5A-82

7. Remove park brake shoe by grasping 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-83

8. Using a screwing motion, rotate the park brake

shoe around the trunnion flange to remove it

from the vehicle.

9. Remove the park brake shoe spring retainer

by prising from the rear disc shield, with a

screwdriver or similar lever.

Figure 5A-84

Techline

10. 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

3.8 REAR DISC SHIELD, in this Section.

REINSTALL

1. Apply Molybdenum Disulphide grease, to

Holden's Specification HN1587 to the

adjusting screw and pins. Fully wind screw

into sleeve and install into the adjuster body.

2. Install the park brake shoe over the trunnion

flange.

3. With one shoe end loc ated on the adjus ter pin,

roll the shoe to engage the other end onto the

other pin.

Figure 5A-85

4. Install park brak e s hoe retaining spring c lip, by

sliding it into place, ensuring that the spring

clip is c orrec tly located by the tangs in the r ear

brake shield.

Figure 5A-86

5. Adjust each park brake shoe diameter to a

dimension of 189.3 - 189.6 mm, using the

screw adjuster.

NOTE:

The trunnion has been omitted from the illustration

for clarity.

6. Install brake discs and check that no drag is

present.

7. Install caliper anchor plate attaching bolts and

tighten to the correct torque specification.

REAR BRAKE CALIPER ANCHOR

PLATE BOLT 70 - 100 Nm

TORQUE SPECIFICATION Figure 5A-87

8. Adjust park brake cable, refer to

2.2 PARK BRAKE CABLE, ADJUST in this

Section.

9. Install road wheels, aligning marks made prior

to removal, install and tighten attaching nuts.

10. Remove safety stands and lower vehicle.

11. Tighten road wheel attaching nuts to the

correct torque specification.

ROAD WHEEL ATTACHING NUT 110 - 140

TORQUE SPECIFICATION Nm

12. Refit wheel covers/centre caps.

3.7 FRONT DISC BRAKE SHIELD

CAUTION :

Whenever any component that forms part of the ABS (if fitted) is disturbed during Service

Operations, it is vital that the complete ABS system be checked, using the procedure as

detailed in DIAGNOSIS, ABS FUNCTION CHECK, in Section 12L ABS & ABS/ETC.

REMOVE

1. Raise front of vehicle and support on safety

stands under the front crossmember.

2. Remove front wheel cover (steel wheels) or

centre cap (alloy wheels) from side of vehicle

where the shield is to be removed.

3. Mark relationship of wheel to hub/brake disc.

Remove road wheel attaching nuts and

remove wheel.

4. Remove front brake caliper anchor plate to

front strut knuckle attaching bolts, remove

caliper from disc.

NOTE: Dis card the front brak e caliper anchor plate

retaining bolts as they must be replaced on

reassembly.

5. Using wire, tie up caliper to lower end of front

suspension coil spring. DO NOT ALLOW

CALIPER TO HANG BY BRAKE HOSE.

Figure 5A-88

6. Remove front brake disc from the wheel

bearing hub.

IMPORTANT:

Marking the relationship of the front brake disc to

the front hub is critical to minimising the possibility

of brake shudder. Refer to 3.4 BRAKE DISC

(FRONT AND REAR) in this Section, for further

information.

NOTE:

For vehicles equipped with ABS, disconnect the

wheel speed sensor connector from the steering

knuckle. To do this, use a 5 mm Allen key (or

socket), remove the set screw and then, holding

the cable retaining bracket, twist and gently pull on

the sens or c onnec tor end. Don't los e the sealing O-

ring.

7. Using a commercially available 10 mm Allen

key socket and a suitable socket bar, loosen

each of the three bolts holding the hub to the

steering knuckle support.

NOTE 1:

For the front lower hub bolt, turn wheel outwards to

provide clearance between the ball joint rivet and

the hub bolt.

NOTE 2:

If the Allen key socket is too long to fit into the front,

upper hub bolt, then the lower strut to steering

knuckle nut will need to be removed and the bolt

withdrawn.

8. To remove hub from knuckle, it may first be

necessary to tap the loosened bolts to break

the seal. DO NOT STRIKE THE HUB.

9. Remove the three bolts and then the hub f rom

steering knuckle.

10. Remove the three rivets securing shield to

knuckle, by drilling the head from each rivet.

Remove the shield from the knuckle support.

11. Carefully drill out the rivet remainder from the

steering knuckle, using a suitable size drill.

Figure 5A-89

REINSTALL

Installation is the r evers e of the rem oval procedur e,

except for the following points:

1. Install the brake shield to the steering knuckle

support, securing with three, common pop

rivets, using a c ommerc ially available pop rivet

gun. Start with the round hole, to ensure that

the clearance to the brake caliper is correct.

2. Before installing the hub, inspect both mating

surf aces to mak e sur e that they are clean and

free from burrs that could prevent correct

alignment of both parts, once installed.

3. Prior to installation, it is also vital that the

sealing O-ring located around the mounting

flange, is checked to ensure its serviceability.

Failing to adequately seal the hub to steering

knuckle interface, will cause water to be drawn

into the cavity in the steering knuckle, during

the normal heating and cooling cycle of

vehicle operation.

Without ABS:

4. Install the hub assembly to the steering

knuckle.

5. Install the three attaching bolts and tighten to

the correct torque specification.

FRONT HUB TO STEERING

KNUCKLE ATTACHING BOLT 120 - 140 Nm

TORQUE SPECIFICATION

NOTE:

The three hub attaching bolts are micro-

encapsulated with thread sealant and are not to be

re-used m ore than thr ee times. If in doubt, the bolts

should be replaced.

With ABS:

6. Carefully align the sensor connection on the

hub, with the hole in the steering knuc kle, then

install the three hub attaching bolts and tighten

to the correct torque specification.

FRONT HUB TO STEERING

KNUCKLE ATTACHING BOLT 120 - 140 Nm

TORQUE SPECIFICATION

7. Fit the wheel speed sensor connector, then

install the cable retaining bracket set screw

and tighten to specification.

SENSOR CABLE RETAINING

SCREW TORQUE 6 - 14 Nm

SPECIFICATION

All Models:

8. Reinstall brake disc and brake caliper,

tightening attaching bolts to specification.

NOTE: New retaining bolts must be used when

reinstalling the front brake caliper anchor plate.

BRAKE CALIPER ANCHOR 80 - 90 Nm,

PLATE RETAINING BOLTS then turn through

TORQUE SPECIFICATION 40 - 50

9. Reinstall road wheel, aligning the marks made

prior to removal and secure with the attaching

nuts.

10. Remove jack stands and lower vehicle.

11. Tighten road wheel attaching nuts to correct

torque specification.

ROAD WHEEL ATTACHING NUT 110 - 140

TORQUE SPECIFICATION Nm

12. Refit wheel cover/centre cap.

3.8 REAR DISC SHIELD

CAUTION :

Whenever any component that forms part of the ABS (if fitted) is disturbed during

Service Operations, it is vital that the complete ABS system be checked, using the

procedure as detailed in DIAGNOSIS, ABS FUNCTION CHECK, in Section 12L ABS &

ABS/ETC.

REMOVE

1. Using a floor jack under centre of differential

carrier, jack up rear of vehicle then place

safety stands under trailing arms.

2. Remove rear wheel cover (steel wheels) or

centre cap (alloy wheels).

3. Mark relationship of wheel to mounting flange.

4. Remove road wheel attaching nuts and

remove wheel.

5. Release park brake.

6. Thoroughly clean around brake hose to pipe

connection at back ing plate. Disconnect brake

pipe from brake hose at backing plate bracket

and remove brake hose retaining clip.

Figure 5A-90

7. Remove brake caliper anchor plate to trailing

arm attaching bolts and remove caliper from

disc.

Using wire, tie up caliper/s to the lower end of

the shock absorber upper mounting/s. DO

NOT ALLOW THE CALIPER/S TO HANG BY

THE BRAKE HOSE/S.

Remove brake disc.

8. Disconnect the park brake cable from the

actuator arm. See 2.9 REAR PARK BRAKE

CABLES in this Section, for details.

Figure 5A-91

9. Remove trailing arm trunnion flange and

trunnion assembly, refer to

Section 4B, FINAL DRIVE AND DRIVE

SHAFTS for the necessary procedure.

IMPORTANT:

Because the removal procedure of the trunnion

flange will cause the bearing to be brinelled, it

must be replaced on reassembly.

Section 4B, FINAL DRIVE AND DRIVE SHAFTS

also provides the necessary procedure for this

task.

10. Remove park brake shoe assembly. Refer to

3.6 PARK BRAKE SHOE, in this Section.

11. Using Torx bit, Tool No. AU416, remove the

two rear disc shield to upper trailing arm

attaching bolts. Then, using a 15 mm socket,

remove the two lower bolts, that also secure

the park brake actuator assembly.

12. Remove rear disc shield and park brake

actuator assembly from vehicle.

Figure 5A-92

13. In order to disassemble the park brake

actuator assembly (2, 3 and 4) from the rear

disc shield, it will be necessary to carefully

support the disc shield to minimise the

possibility of distortion and press the actuator

assembly from the lower extruded bolt hole

sections of the disc plate.

Figure 5A-93

REINSTALL

Installation of 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 exploded view.

2. While supporting the rear disc brake shield,

install the actuator assembly to the extruded

bolt hole sections, after ensuring that the

actuator mechanism is correctly assembled.

Figure 5A-94

NOTE:

The two shorter, upper bolts have washers that are

to be installed with the cut-out surface facing

around the trailing arm hub outer surface.

3. Install and tighten the four rear disc brake

shield to trailing arm attaching bolts. The two

shorter, Torx bit headed ones to the top and

the two longer hexagon headed to the lower

locations. Tighten all to the specified torque

settings.

NOTE: New, lower, hexagon headed retaining bolts

must be used when reinstalling the rear disc brake

shield to the trailing arm.

REAR DISC BRAKE SHIELD

TO TRAILING ARM Top: 70 - 80 Nm

ATTACHING BOLT Lower: 85 - 90 Nm

TORQUE SPECIFICATION

4. Reinstall the park brake shoe. Refer to

3.6 PARK BRAKE SHOE, in this Section.

5. Reinstall the rear disc and adjust the park

brak e shoe, following the procedure detailed in

3.5 PARK BRAKE SHOE, ADJUST, in this

Section.

Figure 5A-95

6. Install and tighten brake caliper anchor plate

to trailing arm attaching bolts to the correct

torque specification.

BRAKE CALIPER ANCHOR PLATE

TO TRAILING ARM ATTACHING 70 - 100 Nm

BOLT TORQUE SPECIFICATION

7. Install road wheel, aligning marks made prior

to removal and tighten road wheel attaching

nuts

8. Remove jack stands and lower vehicle to the

ground.

9. Tighten road wheel attaching nuts to the

specified torque.

ROAD WHEEL ATTACHING NUT 100 - 125

TORQUE SPECIFICATION Nm

10. Check for brake fluid leaks, repair as

necessary.

4. DIAGNOSIS

X - In d ica te s Ca u s e

X X - Indicates a M ore Possible Cause SYMPTOM

CAUSE

Excessive Brake Pedal Travel

Brake Pedal Travel Gradually Increases

Excessive Brake Pedal Effort

Excessive Braking Action

Brakes Slow to Respond

Brakes Slow to Release

Brakes Drag

Uneven Braking Action (Side to Side)

Uneven Braking Action (Front to Rear)

Scraping Noise from Brakes

Brakes Squeak During Application

Brakes Squeal During a Stop

Brakes Chatter

Brakes Groan at End of Stop

Brake Tell-tale Lamp Glows During a Stop

Leaking Brake Line or C onnection X X X

Leaking Caliper or Piston Line X X X X X

Leaking M aster Cylinder X X X X

Air in Brake System XX X X

C ontam inated o r Im proper Brake Fluid X X X X

Leaking Vacuum S ystem X X X

Restricted Air Passage in Vacuum Booster X XX X

D am aged Vacuum B ooster X X X X XX

Im properly Assembled Vacuum Booster Valving X X X X X X

Wo rn Ou t Dis c P ad s - Re p la c e X X X X X X X X

U neven D isc P ad Wear - Re place or Co rrect X X X X X X X X

C ontam inated D isc P ad - R eplace X X X X X X X X X X

H eat Spotted or S cored B rake Discs X X X X X XX X

O ut-of-P arallel B rake D iscs XX

E xcessive B rake D isc R un-O ut X

B rake A ssem bly A ttachm ents - M issing or Lo ose X X X X X X X X

R estricted B rake Fluid Pa ssage or Sticking C aliper P iston X X X X X X X

Brake Pedal/Linkage Binding or Interference X X X X X

Im properly Adjusted Parking Brake X

Incorrect Front Wheel A lignm en t X X X

In co rre ct T y re P re s s u res X X

Wheel B earing C learance E xcessive X X

Loose Front Suspension and/or Com ponents X X X X X

O ut-of-Balance W heel Assem blies XX

O perator R iding B rake P edal X X X X X X

Techline

5. SPECIFICATIONS

BRAKE FLUID

Type To Holden's Specification HN1796

BRAKE BOOSTER

Make PBR

Type Tandem, Vacuum Suspended

MASTER CYLINDER

Make PBR

Type Tandem

Bore diameter (nominal) 25.4 mm

Crack point 3.1 MPa (stamped on master cy linder

end plug)

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 disc thickness, requiring replacement 25.0 mm

FRONT CALIPER

Make PBR

Type Twin piston, sliding caliper

Bore diameter (nominal) 42.0 mm (each)

Disc pad material Organic, non-asbestos

REAR DISC

Type Solid

Diameter (nominal) 286 + 0.0 - 0.2 mm

Thickness 15.9 mm ± 0.2 mm

Lateral Runout (maximum)

(Rate of change 0.03 mm in 30O rotation max.) 0.05 mm

Minimum disc thickness, requiring replacement 13.9 mm

REAR CALIPER

Make PBR

Type Single piston, sliding caliper

Bore diameter (nominal) 40.5 mm

Disc pad material Organic, non-asbestos

DRUM PARK BRAKE

Make PBR

Type Banksia, single shoe, cable and lever

operated

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

Techline

6. TORQUE WRENCH SPECIFICATIONS

Brake pipe to master cylinder flare nut 8 - 11

Front brake caliper anchor bolt 80 - 90 Nm, plus

40° - 50O turn angle

Rear brake caliper anchor plate bolt 70 - 100

Road wheel attaching nut 110 - 140

Brake caliper guide pin bolt 30 - 34

Brake pedal support shaft nut 50 - 60

Throttle pedal support attaching nut 20 - 25

Park brake lever bolt 35 - 65

Outer front park brake cable bracket

retaining bolt 20 - 25

Brake hose to caliper bolt (Front and

Rear) 32 - 37

Brake pipe to brake hose flared nut (All

positions) 14 - 17

Master cylinder end plug 6 - 14

Brake differential warning switch 2.0

Master cylinder reservoir screw 4.0 - 5.0

Master cylinder attaching nut 15 - 20

Master cylinder bracket nut 15 - 20

Brake booster retaining nut 20 - 25

Shock absorber lower mounting nut 105 - 125

Front hub to steering knuckle bolt 120 - 140

Rear disc brake shield to trailing arm. Upper bolt 70 - 80

Lower bolt 85 - 90

ABS sensor lead to steering knuckle

support screw 6 - 14

7. SPECIAL TOOLS

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

AU416 TORX BIT PREVIOUSLY RELEASED AS

KM322

E7115 ANGLE WRENCH PREVIOUSLY RELEASED

FOR 'J' AND 'V' CARS, AS

TOOL NO. 394.

USED TO TIGHTEN

COMPONENT FASTENERS

WHEN ANGLE TORQUE IS

REQUIRED.