SECTION 5A - STANDARD BRAKES

CAUTION:

This vehicle will be equipped with a Supplemental Restraint System (SRS). A SRS will consist of either

seat belt pre-tensioners and a driver's air bag, seat belt pre-tensioners and a driver's and front

passenger's air b ags o r seat b elt p re-t ension ers, driv er’s an d f ron t p asseng er’s air bag and left and righ t

hand side air bags. Refer to SAFETY PRECAUTIONS, Section 12M Supplemental Restraint System of

this Service Information CD before performing any service operation on, or around any SRS

components, the steering mechanism or wiring. Failure to follow the SAFETY PRECAUTIONS could

result in SRS deployment, resulting in possible personal injury or unnecessary SRS system repairs.

CAUTION:

This vehicle may be equipped with LPG (Liquefied Petroleum Gas). 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 lines, before any service work is carried out on the vehicle. Refer to the LPG leaflet included with

the Owner's Handbook for details or the appropriate Section of this Service Information CD for more

specific servicing information.

1. GENERAL INFORMATION

Standard brake components on VT Series II Models carry over from earlier VT Series Models, with some minor

revisions to accommodate the GEN III V8 engine.

Thes e revisions c onsist of a m inor modif ication to the routing of the brak e pipes and on vehicles with a GEN III V8

engine, a new brake booster vacuum hose.

Also included in this Section is a revised brake disc Service Operation, which includes a detailed procedure for

checking brake disc runout and indexing the brake disc to the hub to prevent brake shudder.

NOTE: Disc and hub indexing involves aligning the point of maximum runout on the hub with the point of least

runout on the brake disc.

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2. SERVICE OPERATIONS

Excluding the brake disc Service Operation, all standard brake Service Operations for VT Series and VT Series II

Models carry over from those detailed in Section 5A STANDARD BRAKES of this Service Inform ation CD, noting

the following:

The torque s pecification quoted f or the park brak e lever bolt, listed in Section 5A STANDARD BRAKES in the VT

Series I Service Information are incorrect. The correct torque specification for these bolts is 35 - 65Nm.

If removal of the brake booster vacuum hose on VT Series Models with GEN III V8 engines becomes necessary,

reference to Figure 5A-1 should be made for the correct routing and retainment of this hose.

Figure 5A-1

1. GEN III brake booster vacuum hose.

2. Retaining clip, brake booster end.

3. Retaining clip, engine manifold end.

Blue spot to be on top.

Ensure hose ends are clamped behind the ridge

on the nipple to prevent hoses from

disengaging.

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2.1 FRONT BRAKE DISC

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 (V6 engine) or Section 12L ABS &

ABS/ETC (GEN III V8 engine) of this Service

Information.

REMOVE

IMPORTANT: T he brake dis c to hub relationship is

carefully matched during production (indexed), to

minimise the effect of a tolerance stack-up, that

could result in disc runout and subsequent brake

shudder.

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

check to see whether a paint daub mark (1) is still

visible on the brake disc hub surface, adjacent to

one of the wheel studs and in alignment with the

two marks (2) on the end of the hub, as shown.

If the paint marks are no longer visible, then

carefully mark the relationship of the brake disc to

the hub for installation. If this precaution is not

taken, then a disc runout condition could be

induced that will cause brake shudder.

NOTE: If the br ake disc is being removed to rec tify

brake shudder, if the brake disc is to be machined

or replaced, or if brake disc to hub m atching is not

evident, the brake disc to the hub must be indexed.

Figure 5A-2

1. Remove brake calliper assembly, refer to 3.3

BRAKE CALLIPER (FRONT AND REAR), in

Section 5A STANDARD BRAKES of the VT

Series I Service Information.

NOTE: It is not necessary to disconnect the brake

hose from calliper. Support the calliper with a wire

hook to avoid strain on the brake hose.

2. If necessary, jar the brake disc loose by

carefully tapping the disc in the centre

between the wheel studs, with a soft faced

hamm er, tak ing care not to dam age the wheel

stud threads.

INSPECT

If the brak e 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 brake 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.

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NOTE 2: After machining, the brak e disc s hould be

ground to achieve a non-circumferential finish of

0.4 to 2.0 microns.

Figure 5A-3

NOTE 3: After machining, the chamfer on the

brake disc outer diam eter must be 45 deg x 1 mm

maximum 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-2

NOTE 4: Replace disc if specifications cannot be

achieved above the minimum disc thickness.

WARNING:

THE NUMBER CAST INTO THE HUB (1) IS THE

MINIMUM SAFE THICKNESS. AT THIS

THICKNESS THE DISC MUST BE REPLACED

MINIM U M BRAKE DISC T HICKNESS 25.0

(REPLACEMENT REQUIRED) mm

Figure 5A-3

Inspect disc as follows:

1. Using a piece of chalk, mark the brake disc

every 30 deg (1).

2. Using a dial indicator (2), check that lateral

run-out of each braking surface does not

exceed 0.04 m m Total Indicated Runout (T IR)

and that the rate of change does not exceed

0.03 mm in 30 deg.

MAX IM UM LATERAL RUNOUT (TIR) 0.04mm

MAX IM UM LATERAL RUNOUT IN 30 DEG 0.03mm

NOTE: This specification is the lateral run-out of a

front brake disc that has been removed from the

vehicle (do not confuse this with brake disc to hub

assembled lateral run-out.

Figure 5A-4

3. Check that both surfaces of the brak e disc (A &

B) are flat within 0.05 mm TIR.

Figure 5A-5

4. Check that disc s ur f aces ar e parallel with each

other to within 0.08 mm, when checked

radially.

NOTE: Taper variation must not exceed 0.08mm

Figure 5A-6

5. Check that total circumferential thickness

variation, (also referred to as Disc Thickness

Variation) at any radius, does not exceed

0.005 mm in 360 deg as the brake disc is

rotated.

NOTE: To measure the thickness variation,

measure both sides of the brake disc for runout

and add the two measurements together.

i.e. In the sample opposite:

Total runout on one side = +0.020mm

Total runout on other side = - 0.015mm

Therefore +0.020 +-0.015 = +0.005mm Figure 5A-7

BRAKE DISC AND HUB INDEXING PROCEDURE

NOTE 1: Brake disc and hub indexing is required in

order to obtain the minimum installed brake disc

runout. Brake disc and hub indexing involves

aligning the point of maximum runout on the hub

with the point of least runout on the brake disc

NOTE 2: This procedure is to be used whenever

reinstalling brake discs that have been rem oved for

machining off car. It must also be used when

installing new brake discs or brake discs that have

been removed for any reason and where the brake

disc to hub matching is not evident.

The procedure consists of three parts as follows:

Part 1. Clean mating surfaces

Part 2. Measure and Match brake disc high point

to hub low point. If these measurements are not

OK, go to Part 3

Part 3. Checking hub mounting face runout

Part 1. Clean mating surfaces

Ensure that brake disc and hub mating surfaces

are free from dirt, corrosion, etc. If required, use

fine emery paper to clean surfaces.

Part 2. Indexing brake disc to hub

1. Fasten the brak e disc onto the hub with wheel

nuts reversed to avoid damage to the tapers,

and nip up with a spanner.

2. Number each of the wheel stud holes on the

front surface of the brake disc from 1 to 5.

Place a chalk mark on the end of the wheel

stud adjacent to the number “1” hole.

Figure 5A-8

3. Set up a dial indicator on a m agnetic bas e and

attach to the strut tube above the brake disc.

Position the pointer about 10 to 15mm inboar d

from the outer diameter of the brake disc.

4. Carefully rotate the brake disc and note the

points of minimum and maximum runout on

the dial indicator. The number of divisions

between these two points is the total indicated

runout. Record this figure together with the

number on the brake disc aligned with the

chalk-marked stud.

5. Remove and reinstall the brake disc with hole

number “2” over the marked stud. Repeat Step

4. This procedure is to be repeated for all 5

hole positions.

6. Mount the brake disc to the hub in the stud

position which recorded the least amount of

runout.

NOTE: If the lowest assembled disc runout

achieved is more than 0.050 mm (50 micron)

then the hub runout should be checked as

detailed in Part 3.

MAX IM U M ASSEMBLED DISC & HUB 0.05

RUNOUT AT DISC OUT ER DIAM ET ER mm

Figure 5A-9

Part 3. Hub runout check

1. Clean the front hub f ace by rubbing lightly with

fine emery paper.

2. Locate the dial indicator on the strut tube and

position the pointer on the hub face about

midway between the spigot and the studs.

NOTE: For this check to be performed to 100 %

accurac y, a flat paralleled surfac e plate attached to

the hub should be used, however, measuring

runout between each of the wheel studs should

suffice.

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

avoid loading the bearing) and note the points

of minimum and maximum runout on the dial

indicator. The number of divisions between

these two points is the total indicated runout.

4. If the runout measured in Step 3 exceeds

0.025 mm (25 micron) then the hub unit

should be replaced.

MAX IM UM RUNOUT AT HUB FACE 0.025

– FRONT HUB mm

Figure 5A-10

REINSTALL

1. Reinstall the brake disc over the wheel studs

in either the pre-marked/indexed position or

the newly indexed position.

2. Ensure anchor plate mounting surfaces are

clean.

3. Position calliper assembly over brake 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 CALLIPER 80- 90 Nm, plus

ANCHOR PLATE BOLT 40° - 50°

TORQUE SPECIFICATION turn angle

6. Depress the brake pedal several times to

bring pads into position against disc.

7. Reinstall road wheels aligning marks made

prior to removal then lower vehicle.

8. Tighten road wheel attaching nuts to the

specified torque and in the order shown.

NOTE: Do not use an impact gun to tighten wheel

nuts unless it is fitted with a torque limiter bar

(commercially available). Failure to correctly tighten

wheel nuts to the correct torque specification may

result in a warped brake disc, which may lead to

development of brake shudder.

ROAD WHEEL ATTACHING NUT 110 - 140

TORQUE SPECIFICATION Nm

Figure 5A-11

2.2 REAR BRAKE DISC

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, (V6 engine) or Section 12L ABS &

ABS/ETC (GEN III V8 engine) of this Service Information.

REMOVE

IMPORTANT: The brake disc to hub relationship is carefully matched during production (indexed), to minimise the

effect of a tolerance stack-up, that could result in disc runout and subsequent brake shudder.

Carefully mark the relationship of the brake disc to the hub for installation. If this precaution is not taken, then a disc

runout condition could be induced that will cause brake shudder.

NOTE: If the brake disc is being removed to rectify brake shudder, if the brake disc is to be machined or replaced,

or if brake disc to hub matching is not evident, the brake disc to the hub must be indexed.

Ensure park brake is fully released.

1. Remove brake calliper assembly, refer to 3.3 BRAKE CALLIPER (FRONT AND REAR), in Section 5A

STANDARD BRAKES of this Service Information CD.

NOTE: It is not necessary to disconnect the brake hose from the calliper. Support the calliper with a wire hook to

avoid strain on brake hose.

2. If necessary, jar the brake 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.

NOTE: It may be necessary to loosen the park brake shoe adjustment, to allow the disc to be removed over the

park brake shoes. Refer to Operation 3.5 PARK BRAKE SHOE, ADJUST, in Section 5A STANDARD BRAKES of

this Service Information CD for details.

INSPECT

If the brake 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 res ur f ace BO TH s ides of dis c .

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 should be non-directional. Park brake

surface finish should be 20 microns.

NOTE 3: Replace the brake disc if specifications

cannot be achieved above the minimum disc

thickness.

MINIM U M BRAKE DISC T HICKNESS 13.9

(REPLACEMENT REQUIRED) mm

WARNING: THE DISC MUST BE REPLACED AT

THIS THICKNESS!

Inspect brake 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 brake disc surface 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 ‘D’ is less than 0.05 mm when

measured from surface ‘A' as shown or when

bolted to the axle and that rate of change does

not exceed 0.03 mm in 30°.

5. Check that maximum circumferential

thickness (also referred to as Disc Thickness

Variation (DTV)) does not vary by more than

0.013 mm at any radius when disc is rotated.

Figure 5A-12

BRAKE DISC AND HUB INDEXING PROCEDURE

NOTE 1: The brake disc and hub indexing is

required in order to obtain the minimum installed

disc runout. Brake disc and hub indexing involves

aligning the point of maximum runout on the hub

with the point of least runout on the disc

NOTE 2: This procedure is to be used whenever

reinstalling brake discs that have been rem oved for

machining off car. It must also be used when

installing new brake discs or brake discs that have

been removed for any reason and where the brake

disc to hub matching is not evident.

The procedure consists of three parts as follows:

Part 1. Clean mating surfaces

Part 2. Measure and Match brake disc high

point to hub low point. If measurements are

not OK, go to Part 3

Part 3. Checking hub mounting face runout

Part 1. Clean mating surfaces

Ensure that brake disc and hub mating surfaces

are free from dirt, corrosion, etc. If required, use

fine emery paper to clean surfaces.

Part 2. Indexing brake disc to hub

1. Fasten the brak e disc onto the hub with wheel

nuts reversed to avoid damage to the tapers,

and nip up with a spanner.

2. Number each of the wheel stud holes on the

front surface of the brake disc from 1 to 5.

Place a chalk mark on the end of the wheel

stud adjacent to the number “1” hole.

Figure 5A-13

3. Set up a dial indicator on a m agnetic bas e and

attach to a pre-fabricated mounting plate (1)

(refer 5. SPECIAL TOOLS in this Section for

pre-f abricated m ounting plate details) bolted to

the calliper attaching points. Position the

pointer of the dial indicator about 10 to 15mm

inboard from the outer diameter of the brake

disc.

4. Carefully rotate the brake disc and note the

points of minimum and maximum runout on

the dial indicator. The number of divisions

between these two points is the total indicated

runout. Record this figure together with the

number on the brake disc aligned with the

chalk-marked stud.

5. Remove and reinstall brake disc with hole

number “2” over the marked stud and repeat

Step 4. This proc edur e is to be r epeated f or all

5 hole positions.

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

position which recorded the least amount of

runout.

NOTE: If the lowest assembled disc runout

achieved is more than 0.080 mm (80 micron) then

the trunnion hub runout should be checked as

shown in Part 3.

MAX IMUM ASSEMBLED BRAKE DISC &

TRUNION HUB RUNOUT AT BRAKE DISC 0.08 mm

OUTER DIAM ET ER – REAR BRAKE DISC

Figure 5A-14

Part 3 Trunion hub runout check

1. Clean the front hub f ace by rubbing lightly with

fine emery paper.

2. Locate the dial indicator on the pre-fabricated

mounting plate bolted to the calliper mounting

points and position the pointer on the hub f ace

as shown, refer Fig. 5A-15.

NOTE: For this check to be performed to 100 %

accurac y, a flat paralleled surfac e plate attached to

the hub should be used, however, measuring

runout between each of the wheel studs should

suffice.

3. Carefully rotate the hub by the wheel studs

and note the points of minimum and maximum

runout on the dial indicator. The number of

divisions between these two points is the total

indicated runout.

4. If the runout measured in Step 3 exceeds

0.060 mm (60 micron) then the trunnion

assembly must be replaced.

MAXIMUM TRUNNION HUB TOTAL

INDICATED RUNOUT 0.06 mm

Figure 5A-15

REINSTALL

1. Reinstall the brake disc over the wheel studs

in either the pre-marked/indexed position or

the newly indexed position.

2. Ensure anchor plate mounting surfaces are

clean.

3. Position calliper assembly over brake 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.

REAR BRAKE CALLIPER

ANCHOR PLATE BOLT 70 - 100 Nm

TORQUE SPECIFICATION

6. Depress the 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

Section 5A STANDARD BRAKES of this

Service Information CD.

8. Reinstall road wheels aligning marks made

prior to removal then lower vehicle.

9. Tighten road wheel attaching nuts to the

specified torque and in the order shown.

NOTE: Do not use an impact gun to tighten wheel

nuts unless it is fitted with a torque limiter bar

(commercially available). Failure to correctly tighten

wheel nuts to the correct torque specification may

result in a warped brake disc, which may lead to

development of brake shudder.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 110 - 140 Nm

Figure 5A-16

3.SPECIFICATIONS

FRONT BRAKE DISC

Type............................................................................ Ventilated

Diameter (nominal)..................................................... 296 + 0.0 – 0.2mm

Thickness................................................................ 28.0 ± 0.15mm

Minimum thickness (replacement required)............ 25.0mm

Maximum circumferential thickness variation (also

referred to as Disc Thickness Variation DTV)) ....... 0.005mm

Maximum taper variation......................................... 0.08mm

Maximum lateral runout (disc removed).................. 0.04mm

Maximum lateral runout in 30 deg (disc removed) 0.03mm

Maximum assembled disc and hub runout at disc

outer diameter......................................................... 0.05mm

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

REAR BRAKE DISC

Type............................................................................ Solid

Diameter (nominal)..................................................... 286 + 0.0 – 0.2mm

Thickness................................................................ 15.9 ± 0.2mm

Minimum thickness (replacement required)............ 13.9mm

Maximum circumferential thickness variation (also

referred to as Disc Thickness Variation DTV)) ....... 0.013mm

Maximum lateral runout........................................... 0.05mm

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

Maximum assembled disc and trunion hub runout

at disc outer diameter.............................................. 0.08mm

Maximum trunnion hub total indicated runout ......... 0.06mm

4.TORQUE WRENCH SPECIFICATIONS

Front Brake Calliper Anchor Plate Bolt ................................. 80 - 90 Nm,

plus 40° - 50°

Rear Brake Calliper Anchor Plate Bolt.................................. 70 - 100

Road Wheel Attaching Nut ................................................... 110 - 140

Park Brake Lever Bolt........................................................... 35 - 65

5. SPECIAL TOOLS

TOOL NO. REF

IN TEXT TOOL DESCRIPTION COMMENTS

NOT APPLICABLE PRE-FABRICATED MOUNTING PLATE The mounting plate shown

can easily be made in-

dealership using a 6mm

thick metal plate.

If using the calliper bolts to

attach the plate to the

trunion, a 17mm spacer will

be required.