SECTION 5A - SERVICE AND PARK

BRAKING SYSTEMS

IMPORTANT:

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

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

CONTENTS

1. GENERAL INFORMATION

1.1 GENERAL DESCRIPTION

1.2 MASTER CYLINDER

DESCRIPTION

CONSTRUCTION

OPERATION

1.3 PROPORTIONIN G VALVE OPERATION

ALL EXCEPT UTILITY

UTILITY LOAD SENSING PROPORTIONING

VALVE

1.4 FRONT AND REAR BRAKES

2. MINOR SERVICE OPERATIONS

2.1 SERVICE NOTES AND CAUTIONS

2.2 PARK BRAKE CABLE, ADJUST

2.3 BRAKE FLUID LEVEL CHECK

2.4 BRAKE SYSTEM BLEED

2.5 BRAKE FLUID, CHANGE

2.6 BRAKE PAD WEAR, CHECK

2.7 BRAKE PADS, REPLACE

BRAKE PAD REMOVAL

FRONT BRAKE PAD INSTALLATION

REAR BRAKE PAD INSTALLATION

BRAKE PAD BEDDING-IN PROCEDURE

2.8 BRAKE PEDAL ASSEMBLY

REMOVE

DISASSEMBLE

REASSEMBLE

REINSTALL

2.9 PARK BRAKE LEVER

REMOVE

REINSTALL

2.10 PARK BRAKE WARNING LAMP

SWITCH

REMOVE

INSPECT

REINSTALL

2.11 FRONT PARK BRAKE CABLE

REMOVE

REINSTALL

2.12 REAR PARK BRAKE CABLE /S

REMOVE

REINSTALL

2.13 FRONT BRAKE HOSE

REMOVE

REINSTALL

2.14 REAR CALIPER BRAKE HOSE

REMOVE

REINSTALL

2.15 REAR BRAKE HOSE

REMOVE

REINSTALL

2.16 BRAKE BOOSTER HOSE & VALVE

ASSEMBLY – V6 ENGINE

REPLACE

2.17 BRAKE BOOSTER HOSE & VALVE

ASSEMBLY – GEN III V8 ENGINE

REPLACE

2.18 LOAD SENSING PROPORTIONING

VALVE – UTILITY

REMOVE

REINSTALL

2.19 BRAKE PRESSURE DIFFERENTIAL

WARNING SWITCH

REMOVE

INSPECT

REINSTALL

3. MAJOR SERVICE OPERATIONS

3.1 MASTER CYLINDER

REMOVE

DISASSEMBLE

CLEAN AND INSPECT

REASSEMBLE

REINSTALL

3.2 BRAKE BOOSTER

REMOVE

REINSTALL

3.3 BRAKE CALIPER (FRONT AND REAR)

REMOVE

DISASSEMBLE

CLEAN AND INSPECT

REASSEMBLE

REINSTALL

3.4 FRONT BRAKE DISC

REMOVE

INSPECT

BRAKE DISC AND HUB INDEXING

PROCEDURE

REINSTALL

3.5 REAR BRAKE DISC

REMOVE

INSPECT

BRAKE DISC AND HUB INDEXING

PROCEDURE

REINSTALL

3.6 PARK BRAKE LINING WEAR, CHECK

3.7 PARK BRAKE SHOE, ADJUST

3.8 PARK BRAKE SHOE

REMOVE

REINSTALL

3.9 FRONT DISC BRAKE SHIELD

REMOVE

REINSTALL

3.10 REAR DISC BRAKE SHIELD

REMOVE

REINSTALL

4. DIAGNOSIS

5. SPECIFICATIONS

6. TORQUE WRENCH SPECIFICATIONS

7. SPECIAL TOOLS

Techline

1. GENERAL INFORMATION

1.1 GENER AL DESCRIPTION

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

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

Except f or thos e v eh icles e qui ppe d with A BS as s tand ar d equ ipment, the f r ont an d rear disc br ak es on M Y20 03 V Y

and V2 Series vehicles, are served by separate brake circuits by means of a tandem master cylinder, working

through a vacuum booster. T he dual brake circuit arrangement is designed to provide adequate braking, should a

fault occur in either circuit.

All MY200 3 VY and V2 Series vehicles are f itted with a Steppe d Tandem , Vacuum Suspended t ype brak e booster

and a 25.4 mm bore master cylinder, regardless of the brake system used. The brake booster is not able to be

serviced and must be replaced if proven to have become defective.

All MY2003 VY and V2 Series vehicle 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 front disc brake caliper is attached to the steering knuckle support by two bolts, as is the front wheel bearing

hub, using three bolts. The front dust shield is also attached to the steering knuckle support by three pop rivets.

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 for the park brake.

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 servici ng deta ils of the ABS Br aking System , ref er to Section 5B in this Service Information.

1.2 MASTER CYLINDER

DESCRIPTION

A ma ster cylinder with a 25 .4 mm (1”) diameter bore is used on all MY2003 V Y and V2 Ser ies vehicl es, regar dless

of the braking system fitted. The only differences being:

a. The m aster cylinder used with ABS has a sc rew in blank ing plug i nstalled into the lower of the two front brake

outlets in the master cylinder.

b. The master cylinder fitted to MY2003 VY Series Utility vehicles does not have a brake proportioning valve

incorpora t ed in to t he master cylinder but us es a s eparate, lo ad sensing pr o porti o nin g val ve , c ou ple d t o the rear

suspension. This ensures that the front to rear braking balance, relative to vehicle load, is maintained.

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

travel. T he m aster cylinder is m ounted to th e vacuum brak e booster whic h in turn, is m ounted to t he eng ine side of

the dash panel.

CONSTRUCTION

This tandem m aster cylinde r arr angement prov ides s e p arate hydraulic c irc u its f or the applic at io n 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 except MY2003 VY Series Utility, a proportioning valve is located in a parallel bore in the same

casting of the master cylinder. This valve is used to maintain the front to rear hydraulic pressure balance. Should

one of the two separate systems fail, a separate piston and brake pressure differential warning switch is

incorporated into the design so that the vehicle operator can be warned of a system malfunction.

The MY20 03 VY Series Ut ilit y has a load s ensing pro portioning valve locat ed at the rear of the veh icle. A pr essure

diff erential spool va l ve replaces the propor tioni ng va l v e, n or mally locat ed in the s ec ond bor e of the master cylind er .

This spool valve can move back and forth to operate the brake pressure differential warning switch, should a

pressure loss occur in either the front or rear brake circuits.

Figure 5A - 1

Legend

1. Reservoir Cap

2. Reservoir Cap Seal

3. Reservoir Sealing Grommets

4. Reservoir Retaining Screw

5. Primary Seal Retainer

6. Primary Seal (L type)

7. Recuperating Guide

8. Primary Piston

9. Primary Piston O-ring

10. Caged Spring

11. Secondary Seals (L type)

12. Secondary Piston

13. Secondary Piston Stop Pin

14. Return Spring

15. Master Cylinder Body

16. Fast Fill Valve O-ring

17. Fast Fill Valve

18. Fast Fill Valve Circlip

19. Brake Pressure Differential

Warning Switch

20. Proportioning Valve (Utility:

Differential Spool Valve)

21. Spool Valve Sleeve

22. Spool Valve Sleeve O-ring

23. End Plug O-ring

24. End Plug

OPERATION

The fast fill (fast pressure build up) valve

incorporated into the master cylinder provides

reduced pedal travel by rapidly overcoming large

low pressure displacements, such as the

advancement of brake pads against the disc with

minimal primary piston travel.

Legend

1. Fast Fill Valve Retaining Circlip

2. Fast Fill Valve O-ring

3. One Way Flap Valve

4. Replenishing Holes

5. Compensating Passage

6. Bal l Va lv e and Seat

7. Ball Valve, Pre Load Disc Spring

8. Rubber Flaps

A To Reservoir

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 volum e, lo w pres sure f luid, f lows over th e

primary piston primary L type seal and into the

smaller bore and ou t to the brak e calipers , catering

for most of the low pressure brake system

displacement with minimal primary piston travel.

Figure 5A - 3

Further primary movement increases the pressure

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 force of the primary piston acting on the secondary piston spring

causes the secondary piston to move forward.

This action on the seco ndar y piston m oving forward r eleases th e centre va lve pin fr om contact with the seco ndary

piston st op pin. W ith the for ce of the centr e valve s pring, and th e releas e of the centre valve pin, the r ubber centre

valve seal is pushed against the front of the secondar y piston inner bore, effectively blocking off the fluid from 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 f luid pressur e influence is t hen registered on the proport ioning valve, then to the fr ont and rear

brake calipers, where the brakes are applied.

Figure 5A - 5

Legend

1. Secondary Piston

2. Centre Valve Seal 3. Centre Valve Pin

4. Secondary Piston Stop Pin A To Reservoir

Front Brake System: When the brake pedal is

released and the secondary piston returns, fluid

recuperation will occur from the reservoir through

the reple nishing ho les in the f ast fill val ve, 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

pressur e in the brak e s ystem.

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 becom es unseated from

the secondary piston bore.

Figure 5A - 7

In all vehicles except the MY2003 VY Ser ies Utility vehicles, brake fluid pressure is equal in each system until the

proportioning valve reaches its designed crack point. If the master cylinder pressure then continues to rise, the

proportioning valve operation changes the front to rear braking pressures, to maintain the designed front to rear

braking balance.

1.3 PROPORTIONING VALVE OPERATION

ALL EXCEPT UTILITY

In the relaxed position, the proportioning valve

piston (8) is held in the valve housing (6) by the

large proportioning spring (9).

The poppet valve (3) is held against the end of its

retainer (2) by a light return spring (1) and brake

fluid is free to pass from the master cylinder,

through the bore of the proportioning valve piston

(6) to the rear brakes at A.

Figure 5A - 8

When master cylinder pressure is increased to the

proportioning valve crack point, brake fluid

pressure from the primary section of the master

cylinder acting on the control piston (5), forces the

proportioning valve piston (2) to move to the plug

end, overcoming the large proportioning spring (3)

and seals against the poppet valve (4). This

prevents any further increase in pressure to the

rear brakes until master cylinder pressure is

increased.

Once seated, the proportioning valve piston (2)

now has a larger diameter than the control piston

(5). As a consequence of this differential area, the

output to t he rear brakes after c rack point has bee n

reached, is less than that applied to the front

brakes.

As master cylinder pressure is further increased

above crack point, the piston (2) oscillates against

the poppet va lve (4) a nd pr oportions the r ear br ak e

pressure to a value lower than the front brakes.

Figure 5A - 9

When the brake pedal is released and the fluid pressure from the master cylinder drops, the pressure of the rear

brake fluid unseats the poppet valve (3), allowing the fluid to return to the master cylinder, refer to Figure 5A - 8.

The large propor tioning s pring (9) then returns the propor tioning valve pis ton and control p iston (4) to the ir relaxe d

positions.

Should a loss of pressure occur in either the front or rear brake system, when the brake pedal is applied, the

proport ioning val ve hous ing (6) will m ove withi n the m aster c ylinder bod y, closi ng the sw itch contac ts on the brak e

pressur e diff er entia l war ni n g switch (7) and thus il luminating the brake fail warnin g light on the instrument panel.

After r epairs have been m ade, applicat ion of a reaso nable f orce to the brak e pedal will autom aticall y centralis e the

proport ioning valve h ousing, opening th e contacts in t he brake pres sure differ ential warning s witch and turning the

brake warning light off.

Utility Pressure Differential Spool Valve

As previously stated, the master cylinder fitted to

Utility vehicles is not fitted with a proportioning

valve. In al l other respec ts, it is similar to that f itted

to other MY2003 VY and V2 Series vehicles.

Instead of a proportioning valve, Utility vehicles

have a differential spool valve (2).

The brake pressure differential warning switch (1)

is m ounted in the mas ter cylinder bo dy (3) with the

spring loaded plunger located in a tapered groove

in the centre of the spool valve (2). With the spool

in a centralised position, the switch contacts

remain open.

Should there be a loss of pressure in either the

front (A) or rear (B) brake system when the brake

pedal is applied, the spool valve will move off

centre, closing the switch contacts and activating

the warning light on the instrument panel.

After repairs have been made and the brake

system has been bled, the pressure in the front

and rear brake systems will equalise (when the

brakes are applied), centralising the spool and

opening the contacts in the brake pressure

differential warning switch (1), turning the brake

warning lig ht off .

Figure 5A - 10

UTILITY LOAD SENSING PROPORTIONING VALVE

Construction

The loa d sens ing propor tio ning valv e is attac hed to

the right hand frame, above the final drive

assembly. The valve torsion spring lever (1) is

attached to the right hand trailing arm rod with a

bracket, cable and hook.

The load sensing proportioning valve senses load

by monitoring the rear suspension ride height, to

regulate the pressure applied to the rear brake

calipers. Maximum line pressure is supplied to the

rear brakes when the vehicle is fully laden, while

lightly loaded conditions provide minimum line

pressure; i.e. line pressure varies in relation to the

weight of the load.

The static spring (3) exerts a force on the end of

the spool valve by means of a lever (4), while a

torsion type sensing spring (1) is attached to the

right-hand trailing arm rod, modifying this applied

force, depending on the axle load.

IMPORTANT: Under no c ircum stances is the st atic

spring tens ion adjustin g sc rew (2) and lock nuts (5 )

to be disturbed nor adjusted, as this adjustment is

set in manufacture.

Figure 5A - 11

Operation

When the vehicle is unladen or lightly loaded, the

torsion spring has the maximum effect and,

together with the static spring f orce, the total apply

force on the plunger and load sensing valve spool

(1) is l o west. This app l y for c e is a ble to position t he

load sensing valve spool (1) to restrict the flow of

fluid through the outlet port (B) to the rear brakes.

However, when the vehicle is loaded, the load

sensing valve spool is positioned so that fluid can

flow unrestricted through the inlet port (A), through

the spool sub-assembly, around the poppet valve

(7) and out via the spool sub assembly sealing seat

(2) and outlet port (B) to the rear wheel brake

calipers.

When the brake pedal is released, inlet pressure

drops, allowing the higher pressure on the rear

wheel side of the sensing valve to force upon the

poppet valve (7), such that the brake fluid can flow

almost unrestricted, back to the master cylinder.

Eventually, the load sensing valve spool (1) is

forced into its released position by the external

spring set up, to fully open the passage between

the front and rear circuit.

Figure 5A - 12

Legend

1. Load sensing valve s pool

2. Load sensing valve s pool sealing seat

3. Load sensing valve end plug

4. Secondary spring

5. Primary spring

6. Load sensing valve boot

7. Load sensing valve poppet and valve

A. Brake fluid inlet

B. Brake fluid outlet

1.4 FRONT AND REAR BRAKES

Both front an d r ear br ake assem blies are c om mon for the stand ard an d AB S systems . An ex plod ed vie w of the twin

piston front caliper is shown in Figure 5A - 13.

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

within t he anchor p late b y m eans of two gu ide pins b olted to the housing. R ubber boots are f itted to the gu ide pins

to exclude moisture, dirt and foreign matter.

The rear br ak e c aliper anc h or plates are bo lte d to th e t r ailing ar m and also ha ve a f loatin g ho us ing , s lid in g o v er 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

pressur e is applied, the pis ton forces the inner pad against the dis c and the reaction of the housing pul ls 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 re lax s uff icientl y for the pads to rem ain in clos e prox im ity to th e disc without dr agg ing. Adj ustm ent for wear

is automatic.

Refer to 2.7 BRAKE PADS, REPLACE, in this Section, for further information regarding brake pad application.

Figure 5A - 13

Legend

1. Caliper Housing

2. Bleed Screw

3. Self Locking Bolt (2 places)

4. Guide Pin (2 places)

5. Guide Pin Boot

6. Anchor Plate

7. Clip ( 2 places)

8. Outer Brake Pad

9. Inner Brake Pad

10. Piston Boot (2 plac es)

11. Piston (2 pl aces)

12. Cylinder Seal (2 pl aces )

2. MINOR SERVICE OPE RATIONS

2.1 SERVICE NOTES AND CAUTIONS

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 T HE BRA KING S YSTEM, THAT ONLY GENUINE PARTS ARE USED F O R REPLACEM ENT

PURPOSES.

Even so, when s er vic ing whee l br ake parts, do not cr eate dus t by grin di ng or s an din g br ake linings, b y clean ing

wheel brak e parts with a dry brush or with com pressed air. Breathing in dust that may contain asbestos fibr es

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 MY2003 VY and V2 Series vehicles is hygroscopic and absorbs moisture

from the air through the br ake hoses etc. The boilin g resistance of the f luid decreases as the moistur e 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

2.5 BRAKE FLUID, CHANGE, in this Section.

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

fluid be stored in small (500 ml) containers and that any surplus fluid remaining in a container after use be

discarded.

NOTE: The only approved brake fluid is Super DOT 4 Plus and is available in 250 and 500 ml containers. If

pressure bleeding equipment is used, it m ust 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 come into contact with a

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

c. W henever an y component that forms part of the ABS (if fitted) is dis turbed d uring Ser vice Operat ions, it is vital

that the complete ABS system be checked, refer to 4.4 ABS & TCS FUNCTION CHECK (V6 engines) or

5.4 ABS & TCS FUNCTION CHECK (GEN III V8 engines), in Section 5B, ABS & TCS.

d. W henever a r oad whee l an d/or brake rotor is r em oved f r om or ins talled to a MY2003 V Y or V2 Ser ies ve hic le, it

MUST be done in accorda nce with the procedure provided in 2.3 WHEEL REMOVAL AND INSTALL ATION in

Section 10, WHEELS AND TYRES.

e. W henever a road wheel and/or brake disc is removed from the vehicle, the relat ionship of the road wheel and

the disc to th e hu b MU ST be m ark ed with a felt ti pp ed pen or s imilar, in ord er f or those par ts to b e r eins ta lled in

their original positions. This is critical to maintain the brake disc and road wheel runout dimension to a

minimum.

When reinstalling road wheels, do not use an

impact gun to tighten wheel nuts unless the

impact gun is fitted with a torque limiter socket

(Tool No. AU534 or a commercial equivalent).

Failure to correctly tighten wheel nuts to the

correct torque specification and in the correct

order, may result in a distorted brake disc,

leading to the development of brake shudder.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 100 – 125 Nm

For a com plete desc ription of the method used

to measure both brake disc and trunnion

assembly runout and correction, refer to

3.4 FRONT BRAKE DISC or 3.5 REAR

BR AKE DISC, in this Sec ti on.

Figure 5A - 14

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. App ly the park brak e until the l ever is extende d

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 adjustment,

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 b y the above m ethod, it will be necessary

to refer to 3.7 PARK BRAKE SHOE, ADJUST in

this Section.

Figure 5A - 15

2.3 BRAKE FLUID LEVEL CHECK

Check that the fluid level is between the MIN and

MAX level markings on the translucent reservoir

housing.

NOTE: If the fluid is between the markings, do not

remove reservoir cap, as brake fluid exposed to the

atmosphere will quickly absorb moisture.

Should the addition of f luid be required, wipe clean

the sides of the reservoir cover, then unclip and

rem ove the res ervoir cap . T op up fluid using h eavy

duty brake fluid that complies with DOT 4 Plus

(SAE J1704).

T20B014

Figure 5A - 16

2.4 BRAKE SYSTEM BLEED

LT Section No. – 04-725

The f r ont chamber of the m as ter cylinder can be b led b y lo oseni ng the pi pe to t h e LHF br ak e at th e master c ylinder

(2) and allowing brake fluid to drip from the connection for approximately one minute, ensuring that spilled fluid

drips into a suitab le conta iner. Do not r e-use dra ined fluid and do not operate the brak e pedal or a pply press ure 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 a commercially available pressure bleed cap.

NOTE: View A is for RHD vehicles, while View B is for LHD vehicles.

Figure 5A - 17

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

3. Open brake bleeder of line to be bled and pump brake pedal one stroke/second for approxim ately 10 strokes,

then close ble eder . Dur ing t his oper a tio n the pres s ure bleeder to th e master c ylinder s hould not b e tur ne d of f. 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.

NOTE: View A shows the brake bleeder location for the front brake caliper, while View B is for the rear.

Figure 5A - 18

Techline

2.5 BRAKE FLUID, CHANGE

NOTE: The following fastener MUST be replaced

!) when performing this operation :

Front brake caliper anchor plate to steering

knuckle attaching bolt

REMOVE

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 fluid is free of air. Collect discharged fluid in suitable

container and then discard. Do not allow fluid to contact paintwork.

6. Reconnect wheel brake lines to master cylinder and tighten to specified torque.

BRAKE PIPE TO MASTER CYLINDER

FLARE NUT TORQUE SPECIFICATION 8 - 11 Nm

NOTE: View A is for RHD vehicles, while View B is for LHD vehicles.

Figure 5A - 19

Drain brake calipers as follows:

7. Raise veh icle and plac e on safet y sta nds. Refer to Section 0A GENERAL INFORM AT ION in the MY2003 VY

and V2 Series Service Information for the locations of jacking and support points.

8. Mark position of wheels relative to hub and remove wheels.

9. Loosen the left hand front caliper bleed screw (bold arrow, in Figure 5A - 18).

10. Remove front left hand caliper anchor plate

retaining bolts.

Figure 5A - 20

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 PLATE BOLT

TORQUE SPECIFICATION 80 - 90 Nm, then

40° - 50° turn angle

14. Repeat steps 8 to 13 for the rem aining cali per assem blies and tighten the r ear brak e caliper anc hor plate b olts

to the correct torque specification.

REAR BRAKE CALIPER ANCHOR

BOLT TORQUE SPECIFICATION 70 - 100 Nm

15. Bleed brake system, refer to 2.4 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 ATT ACHING

NUT TORQUE SPECIFICATION 100 - 125 Nm

2.6 BRAKE PAD WEAR, CHECK

FRONT OR REAR

NOTE: The procedure and minimum thickness specification is common to both f ront and rear brak e pads, despite

the fact that only the front brake caliper procedure is provided.

1. Raise the vehicle and support on safety stands. Refer to Section 0A GENERAL INFORMATION in the

MY2003 VY and V2 Series Service Information for the locations of jacking and support points.

2. Remove rear wheel covers (steel wheels) or wheel nut decorative caps (alloy wheels).

3. Mark position of road wheels relative to hub, remove road wheel attaching nuts, then the road wheels.

4. Remove the pads to be checked, from the

caliper ensuring that the original pad positions

are noted. Refer to 2.7 BRAKE PADS,

REPLACE, in this Section.

5. Using vernier calipers, check the brake [pad

thickness in the four locations shown. The

minimum lining thickness should be no less

that the thickness specified. Also, pad wear

should be even – if not, then the cause must

be established and corrected.

BRAKE PAD MINIMUM LINING

THICKNESS BEFORE REPLACEMENT 2 mm

6. If not being replaced, reinstall the brake pads

in the same locations, prior to removal. Refer

to 2.7 BRAKE PADS, REPLACE, in this

Section, for the required procedures for this

operation.

7. Reinstall wheel nuts but do not fully tighten at

this time.

Figure 5A - 21

8. Lower the vehicle to the ground and tighten the wheel nuts to the specified torque, working in a star pattern,

refer to 2.1 SERVICE NOTES AND CAUTIONS, in this Section.

9. Reinstall wheel covers (steel wheels) or wheel nut decorative caps (alloy wheels).

10. Road test vehicle to check for correct brake operation.

2.7 BR AKE PADS, REPLACE

LT Section No. – 04-750 and 04-825

NOTE: The following fasteners have micro-

encapsulated sealant applied and should be

replaced (#

#) on reassembly:

# Brake caliper guide pin bolt

BR AKE PAD REMOV AL

NOTE: T his proc edure ref ers to f ront brak e pads. An y dif ferenc es relatin g to rear brak e pad repl acem ent are noted

in square brackets.

1. Remove m aster c ylinder re servoir cap. L oosen fr ont left (1) [or rear (2)] wheel brak e line connect ion at m aster

cylinder, allowing fluid to bleed into a container until master cylinder reservoir is approximately 1/2 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 braking

system.

NOTE 2: DO NOT ATTEMPT TO RE-USE the removed fluid.

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 will damage paint-work.

NOTE 5: View A is for RHD vehicles, while View B is for LHD vehicles.

Figure 5A - 22

2. Raise fr ont (or rear) of vehi cle and place on s afety stands. Ref er to Section 0A GENERAL INFORM ATION in

the MY2003 VY and V2 Series Service Information for the necessary procedures.

3. Mark relationship of wheel to hub. Remove front (or rear) wheels.

4. Using G-clamps as shown, tighten until the caliper pistons bottom in each bore.

NOTE 1: 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.

NOTE 2: View A is for the front brake caliper, while View B is for the rear.

Figure 5A - 23

5. Us ing a s uitab le si ze ope n end sp anner to hol d

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 free movement 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 an y dirt f rom both t he 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 - 24

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, self locking bolt to the correct torque specification.

#) GUIDE PIN BOLT

TORQUE SPECIFICATION 30 - 34 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 wed ge a n yth ing bet ween the guid e p i n hex a nd t he c a lip er as it c ould c aus e inc orr ec t a lignm ent of

the pin which would then restrict 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 an d hold the br ake peda l down in the applied pos ition for at least 5 s econds, to ens ure 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.

10. Tighten road whee l att ac hi ng nuts to th e s pec if ied torque, work ing i n a star patte r n, as detai le d in 2.1 SERVICE

NOTES AND CAUTIONS, in this Section.

ROAD WHEEL ATT ACHING

NUT TORQUE SPECIFICATION 100 - 125 Nm

11. Reins t al l wheel caps (steel whee ls) or wheel nut dec or ati ve ca ps (al loy wheels) .

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. For example:

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

fingers of the brake caliper housing), has a full

shim.

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

asymmetrical cut-out above the caliper piston

and mus t be cor rectl y installed to the c aliper b y

having the cut-out on the lower half of the pad

when installed in the caliper (in-car position).

The brake pads illustrated, should only be fitted

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

attitude, as shown.

1. Reinstall caliper housing over brake pads.

Ensure spring clip is located correctly in the top

of the caliper body.

2. Install new guide pin, self locking bolt. Tighten

to the specified torque.

#) GUIDE PIN BOLT

TORQUE SPECIFICATION 30 - 34 Nm

NOTE 1: Use a suitable open end spanner to

prevent t he guide p in from rotating when tig htening

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 then

restrict the free sliding of the caliper relative to the

anchor plate.

3. Fill master cylinder to correct level with fresh,

specified brake fluid.

4. Depress brake pedal several times to bring pad

assemblies into position against disc.

5. Refill master cylinder if necessary.

6. Reinstall wheels, aligning marks made prior to

removal and lower vehicle to the ground.

Figure 5A - 25

7. Tighten road wheel attaching nuts to the specified torque, working in a star pattern (refer to 2.1 SERVICE

NOTES AND CAUTIONS, in this Section.

ROAD WHEEL ATT ACHING

NUT TORQUE SPECIFICATION 100 - 125 Nm

8. Reinstal l whee l caps (stee l whee ls ) or wheel nut dec orative caps (alloy wheels).

BRAKE PAD BEDDING-IN PROCEDURE

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

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

km/h every 500 metres.

NOTE 1: A panic stop would be classif ied as being a 0.9 g deceler ation br aking effor t, so a moder ate deceler ation

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.

2.8 BRAKE PEDAL ASSEMBLY

LT Section No. – 04-600

REMOVE

CAUTION: Disable the SRS (Air Bag). Refer to Section 12M, OCCUPANT PROTECTION SYSTEM.

NOTE: For vehicles with manual transmission, it is necessary to remove the clutch pedal assembly prior to

removing the brake pedal assembly. Ref er to Section 7 A1, 3.7 CLUT CH PEDAL ASSEMBLY in the MY2003 VY

and V2 Series Service Information for details.

1. As required, first remove the following components:

a. Driver side instrument panel lower trim plate assembly, refer to Section 1A3, 3.1 INSTRUMENT PANEL

LOWER TRIM PLATE A SSEMBLY.

b. Instrument panel lower trim panel assembly, refer to Section 1A3, 3.4 INSTRUMENT PANEL LOWER

TRIM PANEL ASSEMBLY.

c. Instrument panel lower trim panel retainer, refer to Section 1A3, 3.5 LOWE R TRIM PANEL RETAINER.

2. For left-hand drive vehicles, disconnect the left hand side ventilation ducting. Refer to Section 2B - HVAC

CLIMATE CONTROL (MANUAL AC) – REMOVAL AND INSTALLATION

3. Disconnect t he wiring h arness connec tors from the

stop lamp switch (1) and the cruise control switch

(2).

NOTE: Refer to Section 12E, CRUISE CONTROL for

further information on the cruise control switch.

4. Thoroughly clean the master cylinder, especially

around the brake line connections.

Figure 5A - 26

5. Remove the m as ter c ylinder r eservoir cap. Using a

hand vacuum pum p (1), special tool J 23738- A or a

commercially available hand vacuum pump or

syringe, siphon as much brake fluid from the

master cylinder reservoir (2) as possible.

NOTE: Brak e fluid will c aus e dam age to the pa int work

if it comes into contact with it. In the event that this

happens, wash the brake fluid off with water.

Figure 5A - 27

6. Disconnect the brak e lines (2) f rom the m aster cylinde r (1) and allo w an y residu al brak e f luid from the m aster

cylinder t o drain int o a cont ainer. P lug the ope nings in both the m aster c ylinder and th e pipes to pr event f luid

loss and dirt ingress. Refer to Figure 5A - 28.

NOTE: View A is for RHD vehicles, while View B is for LHD vehicles.

Figure 5A - 28

IMPORTANT: The engine surge tank may be hot.

Allow the coolant to cool before performing this

procedure.

7. For lef t-han d drive veh ic les fitted with th e GEN

III V8 engine, disengage the coolant surge

tank from its anchor points by:

A Grasping the surge tank (1) firmly with

both hands and pivoti ng in the direction of

arrow A to dislodge the surge tank from

the rear anchor po int (2).

B Pulling the surge tank inboard (arrow B)

toward the engine to dislodge the inner

fender skirt anchor point (3). Refer to

2.10 Coolant Recovery Surge Tank in

Section 6B3, ENGINE COOLING – GEN

III V8 ENGINE in the MY2003 VY and V2

Series Service Information for further

information.

8. For lef t-han d drive veh ic les fitted with th e GEN

III V8 engine, disconnect the harness

connector (4) from the coolant level sensor

and set the surge tank to one side.

NOTE: It is not necessary to remove the surge

tank from the vehicle. Leave all hoses and screw-

on-cap intact.

9. To provide access to the brake master

cylinder support bracket on left-hand drive

vehicles fitted with the GEN III V8 engine, it is

necessary to remove the Powertrain Control

Module. Refer to 2.1 Powertrain Control

Module (PCM) in Section 6C3-3, SERVICE

OPERATIONS – GEN III V8 ENGINE in the

MY2003 VY and V2 Series Service

Information.

Figure 5A - 29

10. Remove the bracket securing the master cylinder to the adjacent strut tower. Refer to Figure 5A - 30.

NOTE: View A is for RHD vehicles, while View B is for LHD vehicles.

Figure 5A - 30

11. Disconnect the accelerator pedal cable from the accelerator pedal. Refer to Section:

• Section 6C3- 3 SERVICE OPER ATION S for vehicles fitted with the GEN III V8 engine.

• Section 6C1- 3 SERVICE OPERATION S for vehicles fitted with the V6 and V6 Supercharged engine.

12. Remove the nut (1), four places, securing the

accelerator pedal assembly to the dash panel.

Remove the accelerator pedal assembly.

13. Remove the remaining two nuts (2) securing

the brake booster to the dash panel.

Figure 5A - 31

14. Remove the push rod retaining clip (1), push

rod (3) and washers (2 and 4) from the brake

pedal.

15. Remove the three bolts (3) securing the brake

pedal assembly to the steering column. Refer

to Figure 5A - 31.

16. From the engine compartment, pull the brake

booster forward, allowing the brake pedal

assembly to be lowered, rear end first from

under the instrument panel.

Figure 5A - 32

DISASSEMBLE

1. Remove the nut (1) and washer (2) securing

the brake pedal shaft (3) to the brake pedal

support (5).

2. Carefully remove t he s haf t and was her ( 4) f r om

the brake pedal support.

3. W ithdraw the brak e pedal (8) and retur n spring

(7) assembly.

REASSEMBLE

1. Lubricate all bearing surfaces with

Molybdenum Disulphide grease, as indicated

by the symbol .

2. Hold the brake pedal and return spring in

position and insert the brake pedal support

shaft and washer through the brake pedal

support.

3. Reinstall the brake pedal shaft retaining

washer and nut, then tighten to the specified

torque.

PEDAL SUPPORT SHAFT NUT

TORQUE SPECIFICATION 50 - 60 Nm

Figure 5A - 33

REINST ALL

1. Reinstall the brake pedal assembly into the vehicle and install the three bolts securing the brake pedal

assembly to the steering column, refer to Figure 5A - 31. DO NOT tighten the bolts at this time.

2. Push the brake booster rearward to engage the four studs with the brake pedal assembly.

3. Install the push rod (3), washers (2 and 4) and retaining clip (1). Refer to Figure 5A - 32.

4. Install the accelerator pedal assembly, refer to Figure 5A - 31.

5. Install and tighten the four brake pedal assembly to brake booster nuts to the specified torque. Refer to

Figure 5A - 31.

BRAKE PEDAL ASSEMBLY TO

BRAKE BOOSTER NUT

TORQUE SPECIFICATION 20 - 25 Nm

6. Install and tighten the two accelerator pedal assembly to dash panel nuts to the specified torque. Refer to

Figure 5A - 31.

ACCELERATOR PEDAL ASSEMBLY

TO DASH PANEL NUT

TORQUE SPECIFICATION 20 - 25 Nm

7. Reinstall the accelerator cable. Refer to Section:

• Section 6C3- 3 SERVICE OPERATION S for vehicles fitted with the GEN III V8 engine.

• Section 6C1- 3 SERVICE OPERATION S for vehicles fitted with the V6 and V6 Supercharged engine.

8. Tighten the three brake pedal assembly bolts to the specified torque, refer to Figure 5A - 31.

BRAKE PEDAL SUPPORT BOLT

TORQUE SPECIFICATION 20 - 25 Nm

9. Install the m aster c yl inder support brack et, tightening the fasteners to the s pecified torqu e, refer to Figure 5 A -

30.

MASTER CYLINDER BRACKET

NUT TORQUE SPECIFICATION 15 - 20 Nm

10. For lef t-han d dri ve vehicles f itted with the G EN III V8 e ngi ne, re insta ll th e PCM. Refer to 2.1 P o wertrain C ont rol

Module (PCM) in Section 6C3-3, SERVICE OPERATIONS – GEN III V8 ENGINE in the MY2003 VY and V2

Series Service Information.

11. For left-hand drive vehicles fitted with the GEN III V8 engine, reinstall the coolant surge tank. Refer to 2.10

Coolant Recovery Surge Tank in Section 6B3, ENGINE COOLING – GEN III V8 ENGINE in the MY2003 VY

and V2 Series Ser v ice Infor mation.

12. Place a clean container under the brake master cylinder, unplug the brake lines and master cylinder outlet

ports and reinstall the pipes to the master cylinder, refer to Figure 5A - 28.

13. Tighten the brake pipe nuts to their specified torque.

BRAKE PIPE TO MASTER

CYLINDER FLARED NUT

TORQUE SPECIFICATION 8 - 11 Nm

14. Bleed the brake system. Refer to 2.4 BRAKE SYSTEM BLEED.

15. Adjust the stop lamp and/or cruise control switches as follows:

Stop Lamp Switch

W ith the pedal (1) held i n the at res t position, pus h or pull the s witch ( 2) through t he metal c lip (3) to ach ieve a

gap of 6 ± 0.5 mm, as shown, between the brake pedal support (4) and switch body. Refer to Figure 5A - 34.

Figure 5A - 34

Cruise Control Switch

Check that the tubular clip (1) is correctly

installed. With the brake pedal (2) held in the

depressed position (brakes applied), push the

cruise contro l s witch (3) for ward u ntil t he s witch

body contacts the tubular clip.

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 long er be he ard. At this point, t he switch

will be correctly adjusted.

Figure 5A - 35

16. For left-hand drive vehicles, reinstall the left-hand side ventilation duct.

17. Reinst all the instrum ent panel lower trim panel retainer, lower trim panel and driver side lower trim plate, refer

to Section 1A3, INSTRUMENT PANEL & CONSOLE.

CAUTION: Enable the SRS (Air Bag). Refer to Section 12M, OCCUPANT PROTECTION SYSTEM.

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

2.9 PARK BRAKE LEVER

LT Section No. – 04-675

REMOVE

1. Remove the right hand front seat. Refer to Section 1A7 SEAT ASSEMBLIES in the MY2003 VY and V2

Series Service Information.

2. Set the park brake in the fully released position.

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

then remove the park brake front cable

adjusting nut (2), using a deep socket.

4. Whilst holding the park brake lever boot (1) to

one side, use a screwdriver (2) to prise the

park brake warning lamp switch harness

retaining clip (3) from the transmission tunnel.

Refer to Figure 5A - 37.

Figure 5A - 36

Figure 5A - 37

5. Remove the floor console cover assembly. Refer to Section 1A3, INSTRUMENT PANEL and CONSOLE.

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

connector (2). Refer to Figure 5A - 38.

Figure 5A - 38

7. Whilst holding the park brake lever boot (1) to

one side, remove the par k brake lever r e tai ni ng

bolt (2), two places.

8. Carefully lift the park brake lever assembly

upwards to free the cable (2).

9. Remove the lever assembly from the vehicle.

Figure 5A - 39

REINST ALL

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

1. Tighten the park brake lever bolts to specified torque.

PARK BRAKE LEVER BOLT

TORQUE SPECIFICATION 35 – 65 Nm

2. Reinstal l the thread ed end of the front park brake c able and then inst all the adj usting lock nut. Adjust the park

brake cable. Refer to 2.2 PARK BRAKE CABLE, ADJUST in this Section.

2.10 PARK BRAKE WARNING L AMP SWITCH

LT Section No. – 04-675

REMOVE

1. Remove the park brake lever. Refer to 2 .9 P ARK BR AKE LEVER, REM O VE in this Section.

2. Remove the park brake warning lamp switch

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

Figure 5A - 40

INSPECT

1. Whilst holding the park brake warning lamp

switch (1), depress and release the plunger (2),

checking that the plunger moves freely.

2. Using a multimeter, check that there is

continuity between the terminal (3) and the

switch body.

3. With the multimeter still connected, check that

there is no continuity when the switch plunger

is depressed.

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

brake warning lamp switch.

Figure 5A - 41

REINST ALL

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

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

PARK BRAKE WARNING LAMP

SWITCH RETAINING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

NOTE: For further information on the park brake warning lamp operation, refer to Sect ion 12C, INST RUMENTS.

2.11 FRONT P ARK BRAKE CABLE

LT Section No. – 04-675

REMOVE

1. Set park brake in the fully released position.

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

SEAT ASSEMBLIES in the MY2003 VY and

V2 Series Service Information for the

procedure.

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

2.9 PARK BRAKE LEVER, in this Section.

4. Remove the centre console and lift the carpet

to gain access to the two front cable

escutcheon screws (3). Refer to Section 1A3

INSTRUMENT PANEL and CONSOLE, in the

MY2003 VY and V2 Series Service

Information, for details.

5. Remove the two screws (3).

Figure 5A - 42

6. Raise vehicle and place safety stands under

each of the rear trailing arms. Refer to

Section 0A, GENERAL INFORMATION, in the

MY2003 VY and V2 Series Service Infor mation

for the recommended support points.

7. Pull each park brake inner rear cable forward

and up (1) to release it from the equaliser

bracket. Pull the outer cables to the rear (2) to

remove the cable from the retaining bracket.

8. Remove the front cable outer cable retaining

bracket bolt (4) from the vehicle underbody,

refer to Figure 5A - 42.

NOTE: Depending on the engine/transmission

fitted to the vehicle, it may be necessary to first

remove the propeller shaf t to enable access to this

bolt. Refer to Section 4C PROPELLER SHAFT

AND UNIVERSAL JOINTS, in the MY2003 V Y an d

V2 Series Service Information for the procedure.

9. Manoeuvre the front cable assembly and

equaliser bracket, through the aperture in the

floor pan, removing the cable assembly from

inside the vehicle.

Figure 5A - 43

REINST ALL

Installation is the reverse to the removal procedure,

apart from the following:

1. Manoeuvr e the front cable and equaliser bracket

assembly, through the hole in the floor pan,

ensuring that the rubber seal is correctly

positioned. Install the two self tapping screws

(3 in Figure 5A - 42), securing the plate to the

floor pan.

2. Reinstall the park brake lever and tighten bolts

(2 in Figure 5A - 42) to the specified torque.

PARK BRAKE LEVER BOLT

TORQUE SPECIFICATION 35 – 65 Nm

3. Reinstal l the park br ake f ront cable adj usting nut

a few threads to secure the cable.

4. Reinstall the outer front cable retaining bracket

bolt to the vehicle underbody, tightening to the

specified torque.

OUTER FRONT CABLE BRACKET

BOLT TORQUE SPECIFICATION 6 - 14 Nm

5. As required, reinstall the propeller shaft. Refer to Section 4C PROPELLER SHAFT AND UNIVERSAL

JOINTS, in the MY2003 VY and V2 Series Service Information for the procedure and the specified torque

specifications.

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

Section 1A3 INSTRUMENT PANEL and CONSOLE, in t he M Y20 03 V Y a nd V 2 Ser i es S er v ic e I nf ormation f or

the necessary procedures.

7. Reinstall the two rear cables to the equaliser bracket.

8. Adjust the park brake. Refer to 2.2 PARK BRAKE CABLE, ADJUST in this Section.

9. Lower the vehic l e to the ground.

2.12 REAR PARK BRAKE CABLE/S

LT Section No. – 04-675

REMOVE

1. Release park brake.

2. Using a deep socket, loosen the front 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 - 44

4. To provide sufficient access, it may be

necessary to remove the propeller shaft from

the vehic le. Refer to Section 4C PROPELLER

SHAFT AND UNIVERSAL JOINTS, in the

MY2003 VY and V2 Series Service Infor mation

for the necessary procedures.

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

gromm ets from the underb ody clip/s (1), to f ree

the cable/s (2).

Figure 5A - 45

6. Remove the front of the rear inner cable/s, by

first wrapping rag around the inner cable to

protect it from damage, then use pliers to pull

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

the equaliser bracket.

7. Pull the outer cable rearward (2) to release

from the vehicle underbody bracket.

Figure 5A - 46

8. Disconnect the rear clevis from the rear park

brake actuating lever by gripping with pliers

and pivoting the cable rearwards.

9. Pull outer cable forward, out of trailing arm

retainer/s and remove the cable/s from the

vehicle.

Figure 5A - 47

REINST ALL

Reinstallation 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. If removed, reinstall the propeller shaft. Refer to Section 4C PROPELLER SHAFT AND UNIVERSAL JOINTS,

in MY2003 VY and V2 Series Service Information for all details.

4. Adjust park brake cable, refer 2.2 PARK BRAKE CABLE, ADJUST, in this Section.

2.13 FRONT BRAKE HOSE

LT Section No. – 04-750

REMOVE

1. Raise fr ont of ve hic le and place o n j ack stands.

Refer to Section 0A, GENERAL

INFORMATION, in the MY2003 VY and V2

Series Service Information for the

recommended support points.

2. Mark position of wheel relative to hub and

remove road wheel.

3. Thoroughly clean connections at each end of

brake hose (1).

4. Disconnect brake pipe (2) from hose (1) and

plug pipe.

5. Remove the screw (3) securing the hose

bracket to the inner skirt panel.

6. Unclip hose and grommet (4) from bracket on

suspension tower.

7. Unbolt and remove the brake hose from the

caliper, refer to Figure 5A - 49.

Figure 5A - 48

REINST ALL

1. Ensure brake hose and c a li per mating surf ac es

are clean and free from burrs.

2. Reconnect brake hose (1) to caliper, using

NEW copper sealing washers (3), then tighten

the banjo bolt (2) to specified torque.

BRAKE HOSE TO CALIPER

TORQUE SPECIFICATION 32 - 37 Nm

3. Clip hose and grommet into suspension strut

bracket.

4. Reinstall the screw to retain the hose bracket

to the inner skirt panel.

5. Remove plug f rom brake pipe an d rec onnect to

hose. Tighten to specified torque.

BRAKE PIPE TO BRAKE HOSE FLARE

NUT TORQUE SPECIFICATION 14 - 17 Nm

6. Check that hose is not twisted.

Figure 5A - 49

7. Bleed brake/s, refer 2.4 BRAKE SYSTEM

BLEED, in this Section.

8. Reinstall road wheel, aligning marks made on

removal and lower vehicle.

9. Tighten road wheel attaching nuts to the

specified torque, tightening in a star pattern,

refer to 2.1 SERVICE NOTES AND

CAUTIONS, in this Section.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 100 - 125 Nm

2.14 REAR CALIPER BRAKE HOSE

LT Section No. – 04-750

REMOVE

1. Raise the rear of the vehicl e and place o n jack

stands. Refer to Section 0A GENERAL

INFORMATION in the MY2003 VY and V2

Series Service 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 (2).

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 - 50

REINST ALL

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

2. Rec onnec t brak e hos e to c ali per, ens uring that t he locatin g peg alig ns with the di m ple in the cal iper. Us e NEW

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

BRAKE HOSE TO CALIPER

TORQUE SPECIFICATION 32 - 37 Nm

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

NUT TORQUE SPECIFICATION 14 -17 Nm

5. Bleed brake/s, see 2.4 BRAKE SYSTEM BLEED, in this Section.

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

7. Tighten road wheel attaching nuts to the specified torque, tightening in a star pattern, refer to 2.1 SERVICE

NOTES AND CAUTIONS, in this Section.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 100 - 125 Nm

2.15 REAR BRAKE HOSE

LT Section No. – 04-750

REMOVE

1. Raise rear of vehicle and place on jack stands. Refer to Section 0A GENERAL INFORMATION, in the

MY2003 VY and V2 Series Service Information, for the procedure.

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

Figure 5A - 51

Legend

VIEW A: LH Shown – RH opposite

VIEW B: With Traction Control – LH shown, RH opposite

Without Traction Control – LH only

VIEW C: Without Traction Control – RH only

VIEW D: RH shown, LH opposite

Align Flats on Brack et and Hose

1. Rear Brake Pipe

2. Rear Brake Hose, Caliper t o Rear Brake Pipe

3. Rear Brake Hose

4. Retaining Clip

5. Brake Hose Connecti on Pipe

6. Junction Block – RH only (Vehicles without Traction Cont rol )

3. Disc onnect brak e pipe (5) fr om brake hos e (3) at trailing ar m brack ets (View B). Plu g open end of br ake pipe/s

to prevent foreign material entry.

4. Dis connect r ear brak e pipe (1) connectio n f rom br ake hose (3), while hol ding the hose with a back -up spann er.

For those v ehicles witho ut ABS/T CS, the RH sid e brak e hose ( View C), a lso has a junction block (6) to provide

for a connection from the master cylinder. Plug all pipe ends to prevent foreign material entry.

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

NOTE: Refer to Operat ion 2.13 for procedure to remove the rear caliper hose (2).

REINST ALL

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

2. Fit hose (3) into mounting plate brackets and reinstall retaining clips (4). Check that the hose (3) is not twisted.

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

torque.

BRAKE PIPE FLARE NUT

TO BRAKE HOSE

TORQUE SPECIFICATION 14 - 17 Nm

4. Bleed brake/s, see 2.4 BRAKE SYSTEM BLEED, in this Section.

5. Raise vehicle, remove jack stands, then lower vehicle to the ground.

2.16 BRAKE BOOSTER HOSE & VALVE ASSEMBLY – V6 ENGINE

REPLA CE

1. Remove the four decorative nuts securing the engine dress cover, then remove the cover from the engine.

2. Using su itab le pl iers , c ompress the spring h os e c lamp at each end of the br ake booster vacu um hose and sli d e

both clamps back along the hose, refer to Figure 5A - 52 and Figure 5A - 53.

CAUTION: Wear safety glasses to avoid eye injury when working with spring wire hose clamps.

NOTE: View A is for RHD vehicles, while View B is for LHD vehicles.

Figure 5A - 52

3. While supporting the vacuum check valve at

the booster end, twist the hose to break the

seal, then remove by twisting back and forth

while maintaining a constant pulling force on

the hose. Repeat for the intake manifold fitting

at the rear of the engine.

4. Reinstallation is the reverse of the removal

process, except that each hose clip must be

reinsta lled over t he hose a nd behind t he nipple

at each end to prevent hose premature

disengagement.

5. Reinstall the engine dress cover and secure

with the four decorative nuts, tightening to the

correct torque specification.

ENGINE DRESS COVER NUT

TORQUE SPECIFICATION 5 Nm

Figure 5A - 53

2.17 BRAKE BOOSTER HOSE & VALVE ASSEMBLY – GEN III V8 ENGINE

REPLA CE

1. Remove the four engine dress cover

decorative nuts (2), then remove the dress

cover (1) from the engine.

Figure 5A - 54

2. Using su itab le pl iers , c ompress the spring h os e c lamp at each end of the br ake booster vacu um hose and sli d e

both clamps back along the hose, refer to Figure 5A - 55 and Figure 5A - 56.

3. W hile suppor ting the vac uum check valve at the boost er end, t wist the h ose to br eak the s eal, then remove by

twisting back and forth while maintaining a constant pulling force on the hose. Repeat for the intake manifold

fitting at the rear of the engine, supporting the fitting during the removal process.

4. Reinstallation is the reverse of the removal process, except that each hose clip must be reinstalled over the

hose and behind the nipple at each end to prevent hose premature disengagement. Also ensure that the b lue

alignment dot on the hose is facing upward

Figure 5A - 55 – Brake Vacuum Booster Hose – RHD with the GEN III V8 Engine

Legend

1. GEN III V8 brake booster vacuum hose.

2. Retaining cli p, brak e boost er end.

3. Retaining cli p, engine m anifol d end.

Blue spot to be on top.

Ens ure hose ends are clamped behind the ri dge on the nipple.

Figure 5A - 56 – Brake Vacuum Booster Hose – LHD with the GEN III V8 Engine

Legend

1. GEN III V8 brake booster vacuum hose.

2. Retaining cli p, brak e boost er end.

3. Retaining cli p, engine m anifol d end.

Blue spot to be on top.

Ens ure hose ends are clamped behind the ri dge on the nipple.

2.18 LOAD SENSING PROPORTIONING VALVE – UTILITY

REMOVE

1. Raise the rear wheels and place the vehicle on suitable safety stands.

2. Dis connec t the brak e li nes f rom the load sens ing pro por tionin g valve. Seal th e openi ngs and li nes with suit able

plugs.

3. Unhook the load sensing proportioning valve connector cable from the load-sensing arm by moving the arm

downward to relieve the tension. Slowly release the arm.

NOTE: The arm may spring up slightly when the hook is released.

4. Support the load sensing proportioning valve, then remove the nuts from the two retaining bolts and remove

the bolts removing the valve assembly.

Figure 5A - 57

Legend

1. Load sensing proporti oni ng val ve

2. Connector cable assembly

3. Nut (2 places)

4. Mounting bracket bolt

5. Bolt (2 places) 6. Mounting bracket

7. Load sensing arm

REINSTALL

The installation procedure is the reverse of the removal procedure, noting the following:

1. Position valve on brack et, then install and secure the two bolts. Tighten the bo lts or nuts to th e correct torque

specification.

LOAD SENSING VALVE MOUNTING

NUT TORQUE SPECIFICATION 35 - 40 Nm

LOAD SENSING VALVE MOUNTING

BRACKET BOLT

TORQUE SPECIFICATION 55 - 60 Nm

2. Ensure all pipes are secured and routed correctly, refer to Figure 5A - 58.

3. Bleed the brake system refer to 2.4 BRAKE SYSTEM BLEED, in this Section.

NOTE 1:The load sensing proportioning valve setting is preset and should not be adjusted.

NOTE 2:The c able hook must be connec ted to the torsion s pring lever in t he correct or ientation, refer to View B in

Figure 5A - 57

Figure 5A - 58

Legend

1. Brake and fuel line harness

2. Fuel feed and return line

3. Brake hose clip

4. Load sensing proporti oni ng val ve

5. Brake pipe clamp to dash panel bolt

6. Rivet (5 plac es)

7. Nut (4 places)

8. Screw (2 places)

Flats aligned on hose and bracket

2.19 BRAKE PRESSURE DIFFERENTIAL WARNING SWITCH

REMOVE

1. Dis connec t the brak e pres sure dif fer ential warnin g

switch harness connector (1) from the brake

pressure differential warning switch (2).

NOTE: To disconnect the harness connector, spread

the two locking tangs (3) whilst pulling the connector.

2. Unscrew the brake pressure differential warning

switch from the master cylinder.

NOTE: Ensure the earthing spring (4) is attached to

the plunger switch plunger (5).

Figure 5A - 59

INSPECT

1. Check that the earthing spring (1) is firmly

installed on the switch plunger (2).

NOTE: If necessary, the small end of the spring

may need to be closed down slightly to give the

required attachment.

2. Using a multimeter, check that there is no

continuit y between t he ear thing sprin g and the

switch terminal.

NOTE: Although there are two terminal

connections within the switch assembly, these

terminals are bridged together by a small bridging

wire.

3. With the multimeter still connected, check that

there is continuity when the switch plunger is

depressed.

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

pressure differential warning switch.

Figure 5A - 60

REINST ALL

1. Reinstall the brake pressure differential switch (1) to the master cylinder. Refer to Figure 5A - 59.

2. Tighten to the brake pressure differential switch to the specified torque – do not over tighten.

BRAKE PRESSURE DIFFERENTIAL

WARNING SWITCH

TORQUE SPECIFICATION 2 Nm

3. Reconnect the brake pressure differential warning switch harness connector to the brake pressure differential

warning switch.

3. MAJOR SERVICE OPERATIONS

3.1 MASTER CYLINDER

LT Section No. – 04-725

REMOVE

1. Thoroughly clean the master cylinder, especially around the brake line connections.

2. Remove the master cylinder reservoir cap.

Using a hand vacuum pump (1), special tool

J23738-A or a commercially available hand

vacuum pump or syringe, siphon as much

brake fluid from the master cylinder reservoir

(2) as possible.

NOTE: Brake fluid will cause damage to the paint

work if it comes into contact with it. In the event

that this happens, wash the brake fluid off with

water.

Figure 5A - 61

3. Disconnect the electrical connector from the brake pressure differential warning switch.

4. Disconnect the wheel brake lines (2) from the master cylinder (1) and allow any residual brake fluid from the

master cylinder to dr a in int o a c onta in er. Pl ug t he op e nin gs in b oth th e master cylinder and the p ipes to pr ev ent

fluid loss and dirt ingress.

NOTE: View A is for RHD vehicles, while View B is for LHD vehicles.

Figure 5A - 62

IMPORTANT: The engine surge tank may be hot.

Allow the coolant to cool before performing this

procedure.

4. For lef t-han d drive veh ic les fitted with th e GEN

III V8 engine, disengage the coolant surge

tank from its anchor points by:

A Grasping the surge tank (1) firmly with

both hands and pivoti ng in the direction of

arrow A to dislodge the surge tank from

the rear anchor po int (2).

B Pull the surge tank inboard (arrow B)

toward the engine to dislodge the inner

fender skirt anchor point (3). Refer to

2.10 Coolant Recovery Surge Tank in

Section 6B3, ENGINE COOLING – GEN

III V8 ENGINE in the MY2003 VY and V2

Series Service Information for further

information.

5. For lef t-han d drive veh ic les fitted with th e GEN

III V8 engine, disconnect the harness

connector (4) from the coolant level sensor

and set the surge tank to one side.

NOTE: It is not necessary to remove the surge

tank from the vehicle. Leave all hoses and screw

on cap intact.

6. To provide access to the brake master

cylinder support bracket on left-hand drive

vehicles fitted with the GEN III V8 engine, it is

necessary to remove the Powertrain Control

Module. Refer to 2.1 Powertrain Control

Module (PCM) in Section 6C3-3, SERVICE

OPERATIONS – GEN III V8 ENGINE in the

MY2003 VY and V2 Series Service

Information.

Figure 5A - 63

7. Remove the bracket securing the master cylinder to the adjacent strut tower.

8. Remove the nuts securing the master cylinder to the brake booster and remove the master cylinder.

IMPORTANT: DO NOT disturb th e brake boos ter push rod, a nd DO NOT depress the brake ped al with the master

cylinder removed or the internal reaction disc in the booster may become dislodged.

NOTE: View A is for RHD vehicles, while View B is for LHD vehicles.

Figure 5A - 64

DISASSEMBLE

1. Clean the outside of the master cylinder.

2. Remove reservoir cap (1) and seal (2). Discard

any fluid left in reservoir

3. Unscrew the reservoir to body retaining screw

(4), located at the base of the reservoir.

4. Separate the plastic reservoir (3), by hand,

from the body (5).

5. Remove the two reservoir sealing grommets

(6) from the body (5).

Figure 5A - 65

6. Invert master cylinder body (3) so that the

reservoir ports (1) face downwards. Depress

the primary piston (2) with a wood dowel or

brass r od u nti l t he pis t on b ottoms in th e b ore of

the master cylinder body (3). The secondary

piston stop pin (4) should freely fall out.

7. Carefully remove primary piston (2) from the

main bore of the master cylinder (3).

Figure 5A - 66

8. Remove s ec ond ary piston ( 1) and r eturn s pr ing

(2) by lightly tapping the open end of the

master cylinder b ore squar ely onto a sof t piece

of wood.

NOTE 1: The caged spring (3) of the secondary

piston (1) has been set to a predetermined length.

Do not attempt to adjust or remove the caged

spring (3).

NOTE 2: The centre valve is part of the secondary

piston assembly and is not serviced as a separate

part.

Figure 5A - 67

9. Remove the seal retainer (1) from the primary

piston (2), using a small screwdriver to

caref ull y pry apart the seal retain er legs.

10. Remove the recuperating guide (3) and seal

(4) from the primary piston (2).

11. Remove the O-ring (5) seal from the primary

piston (2), taking EXTREME CARE not to

damage the piston in the process.

12. Remove both seals (6) from the secondary

piston (7), again taking EXTREME CARE not

to damage the piston (7).

Figure 5A - 68

13. Using suitable circlip pliers, remove the circlip

(1) retaining the fast fill valve (2) located in the

primary reservoir port of the master cylinder

(3).

14. Face the master cylinder reservoir ports

downwards to allow the fast fill valve (2) to fall

out. If the valve is stuck, lightly tap the master

cylinder on a piece of wood to assist removal.

15. Remove the valve sealing O-ring (4) from the

bottom of the reservoir port.

Figure 5A - 69

16. Unscrew an d rem ove the e nd plug (1) from the

master cylinder body (3).

17. Remove the brake pressure differential

warning switch (5) from the master cylinder,

ensuring that the electrical earthing spring

remains on the switch plunger.

18. Remove the proportioning valve assembly

(differential spool valve assembly – Utility) (6)

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 disass emble the propor tioning va lve

assembly as this valve is only serviced as a

complete assembly.

Figure 5A - 70

CLEAN AND INSPECT

NOTE: Ensure work area is clean and free of dust or other contam inants. These can affect the performance of all

the seals in the master cylinder.

1. Wash master cylinder body, reservoir and cap 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 bore.

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 spring). Only new parts from the genuine

service kit should be used to reassemble the master cylinder.

REASSEMBLE

NOTE 1: Bef ore assembl y, lubricate int ernal parts and m aster cylinder bor es with clean, recom mended brak e fluid

from a sealed container.

NOTE 2: Prior to assembly, ensure that the primary piston, without seals fitted to it, is free to m ove the full piston

stroke in the large bore.

NOTE 3: The three L type seals (6 and 8) must be assembled in the directions and positions as shown next.

Figure 5A - 71

Legend

1. Reservoir Cap

2. Reservoir Cap Seal

3. Reservoir Seal i ng Grommets

4. Secondary Piston

5. Return Spring

6. Secondary Seals (L Type)

7. Caged Spring

8. Primary S eal (L Type)

9. Primary Pist on O-ri ng

10. Primary Piston

11. Fast Fill Valve O-ring

12. Fast Fill Valve

13. Fast Fill Valve Circlip

14. Reservoir

15. Reservoir Cap Retai ning Clip

1. Install O -r ing sea l ( 1) in to the groove at th e end

of the primary piston (2).

2. Install the recuperating guide (3) followed by

the primary L type seal (4) onto the end of the

primary piston (2). The sealing face of the L

type seal must face away from the

recuperat ing 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. As sem ble the s eal ret ainer ( 5) onto the prim ar y

piston (2). Using a small screwdriver, clip the

retainin g legs of the r eta iner ( 5) into the groo ve

on the primary pisto n ( 2). Care shou ld b e taken

to avoid damage to the piston or seal.

Figure 5A - 72

4. Assemble the small end of the return spring

over (1) the end of the secondary piston (2).

This should be a slight int er ference fit.

Figure 5A - 73

5. Carefully insert the secondary piston , caged

spring end las t, throug h the large bor e and into

the sm aller bor e of the master cylinder unti l the

return spring (1) 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 (2) in the

secondary piston with the hole in the reservoir

ports. This must be done so that the secondary

piston stop pin (3) can be inserted into secondary

reservoir port (4) in the master cylinder.

6. Fully stroke the secondary piston using a soft

dowel and, while held at the bottom of the

bore, install the secondary piston stop pin (2)

into the secondary reservoir port (4). The

piston stop pin (3) should easily fit through the

larger of the two holes loc at ed in the sec ond ar y

reservoir port. The top of the secondar y piston

stop pin should not protrude more than 6 mm

above the bottom of the reservoir port.

Figure 5A - 74

7. Ins ert the prim ar y piston (1 ) into the m ain bor e,

against t he secondar y piston a nd caged spr ing

assembly. Carefully push both pistons down

the bore until the primary piston is flush with

the bore opening.

8. Stroke pistons and check that the primary

piston re turns to the end of the bore after eac h

stroke. Ensure movement is not sticky.

Figure 5A - 75

NOTE: While the proportioning valve (or pressure

differential spool valve on Utility) (2) are physically

similar in external appearance, the terminology for

the Utility reassembly is provided in square

brackets.

9. Fit new O-rings (1) onto proportioning valve

[pressure differential spool valve] (2).

10. Ensur e spacer (3) and O- ring (4) ar e fitted over

the proportioning valve spool [pressure

differential spool valve] and that they are

installed in the correct order (spacer first, then

the O-ring).

11. Insert proportioning valve [pressure differential

spool valve] into the bore, capped end [solid

end] A first. Extreme care should be taken

when inserting the valve to ensure that the O-

rings (1 an d 4) are not d amaged. If O-rings are

damaged, the master cylinder will not function

correctly and will leak brake fluid. The

proportioning valve [pressure differential spool

valve] assembly (2) must be bottomed in the

bore of the master cylinder.

12. Assemble a new O-ring (6) onto the end plug

(7), and screw the end plug into the master

cylinder body, tightening to the specified

torque.

END PLUG

TORQUE SPECIFICATION 25 - 30 Nm

Figure 5A - 76

13. Reinstall the brake differential warning switch

and spring. Tighten t o the specified t or qu e – do

not over tighten.

BRAKE PRESSURE DIFFERENTIAL

WARNING SWITCH

TORQUE SPECIFICATION 2 Nm

NOTE: Ensure the earthing spring on the brake

pressure differential warning switch 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.

Figure 5A - 77

14. Carefully install the fast fill valve O-ring (4) in

the bottom shoulder of the primary reservoir

port (3).

15. Fit the fast fill valve (2) into the primary

reservoir port (3), ensuring the rubber base

with six dimples is facing downward. Secure

valve with circlip (1).

Figure 5A - 78

16. Lightly smear the bores of the reservoir ports

and sealing grommets (6) with clean brake

fluid.

17. Carefully assemble sealing grommets (6) into

the bores of the reservoir ports to locate them

against the shoulder in each bore.

18. Reins tall reser voir (3) by pus hing reser voir into

the sealing grommets (6) until the hole for the

retaining screw in the reservoir aligns with the

master cylinder bod y ( 5). In s tall r eta ini ng sc r ew

(4) and tighten to the specified torque. The

retaining screw (4) 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 reservoir

retaining screw to avoid cross threading.

RESERVOIR SCREW

TORQUE SPECIFICATION 4.0 – 5.0 Nm

19. 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.

20. Assemble new reservoir seal (2) into reservoir

cap (1). Lubricate inside of the reservoir lips

with clean brake fluid to accept the reservoir

cap seal.

21. Reinstall cap seal (2) and cap (1).

Figure 5A - 79

REINST ALL

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

1. Reinstal l the master cylinder as s em bly onto th e br ak e boos ter tak ing c are not to dis turb th e br ake booster p u sh

rod.

2. Tighten the master cylinder nuts to the specified torque.

MASTER CYLINDER

ATTACHING NUT

TORQUE SPECIFICATION 15 – 20 Nm

3. Reinstall the master cylinder support bracket and tighten the nuts and bolt to their specified torque.

MASTER CYLINDER TO

BRACKET FASTENER

TORQUE SPECIFICATION 15 – 22 Nm

4. For left-hand dri ve v ehicles f itted with the G EN III V8 e ngine, re ins ta ll th e PC M. Refer to 2.1 P o wertrain C ont rol

Module (PCM) in Section 6C3-3, SERVICE OPERATIONS – GEN III V8 ENGINE in the MY2003 VY and V2

Series Service Information.

5. For left-hand drive vehicles fitted with the GEN III V8 engine, reinstall the coolant surge tank. Refer to 2.10

Coolant Recovery Surge Tank in Section 6B3, ENGINE COOLING – GEN III V8 ENGINE in the MY2003 VY

and V2 Series Ser v ice Infor mation.

6. Place a clean contain er under the m aster c ylinder, un plug the brak e lines and m aster cylinder outlet ports a nd

reinstall the pipes to the master cylinder.

7. Tighten to their specified torque.

BRAKE PIPE TO MASTER

CYLINDER FLARED NUT

TORQUE SPECIFICATION 8 – 11 Nm

8. Reconnect the electrical connector to the brake pressure differential warning switch.

9. Bleed the brakes. Refer to 2.4 BRAKE SYSTEM BLEED, in this Sect ion.

3.2 BR AKE BOOSTER

LT Section No. – 04-725

NOTE: The brake booster is not a serviceable item and if found to be faulty, must be replaced as a unit.

REMOVE

1. Remove master cylinder, refer to 3.1 MASTER CYLINDER in this Secti on.

IMPORTANT: W ith the mas ter cylinder rem oved, do not dist urb the brake boos ter push rod nor depr ess the brak e

pedal, as the reaction disc in the booster may become dislodged.

2. Remove vacuum hose from brake booster vacuum check valve. Refer to 2.16 BRAKE BOOSTER HOSE – V6

ENGINE or 2.17 BRAKE BOOSTER HOSE – GEN III V8 ENGINE, in this Section.

3. Remove instrument panel lower right

trim assembly. Refer to Section 1A3

INSTRUMENT PANEL and CONSOLE, in the

MY2003 VY and V2 Series Service

Information, for details.

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

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

Figure 5A - 80

5. Remove br ake booster ass embly retain ing n uts

(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 - 81

REINST ALL

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

1. Lubricat e brake peda l an d pus h rod c omponent b eari n g s ur f aces with M olybdenu m Disulphide gr e as e. R ef er to

Figure 5A - 33 and the symbol for the locations.

2. Ensure brake booster hose is routed correctly.

3. Reinstall master cylinder. Refer to 3.1 MASTER CYLINDER, in this Section.

4. Tighten brake booster retaining nuts to specified torque.

BRAKE BOOSTER RETAINING

NUT TORQUE SPECIFICATION 20 – 25 Nm

Techline

3.3 BR AKE CALIPER (FRONT & REAR)

LT Section No. – 04-750 and 04-825]

NOTE: The following fasteners MUST be replaced

!) when performing this operation or they have

micro-encapsulated sealant applied and should be

replaced on reassembly (#

#):

Front brake caliper anchor plate to steering

knuckle attaching bolt

Brake caliper guide pin bolt

REMOVE

NOTE: W hile the serv ice oper ation descr ibed, re lates to the f ront brak e c aliper/s , the s am e procedur e can be used

for the rear brake caliper operation.

1. Raise vehic l e and place on j ack stands.

2. Mark position of road wheel relative to hub and remove wheel. Refer to 2.1 SERVICE NOTES AND

CAUTIONS, in this Section.

3. Place a drain tray beneath caliper assembly.

4. Loosen and remove brake hose to caliper

banjo bolt. Separate bolt from hose and

discard sealing washers.

5. Remove the brake caliper anchor plate

retaining bolts and lift the caliper assembly out

over disc .

NOTE: Discard the f ront brak e caliper anchor plate

retaining bolts as they must be replaced on

reassembly.

Figure 5A - 82

6. The removal procedure for the rear brake

caliper is similar to that for the front.

NOTE: The rear brake caliper anchor plate bolts

can be reused on assembly

Figure 5A - 83

DISASSEMBLE

NOTE: Apart from the two spring clips (12) fitted to the front brake calipers (refer to Figure 5A - 84), both the

service operation description and part identification numbers are the same for the front and rear brake calipers.

Front Brake Caliper

Figure 5A - 84

Legend

1. Caliper Housing

2. Bleed Screw

3. Self Locking Bolt (2 places)

4. Guide Pin (2 places)

5. Guide Pin Boot

6. Anchor Plate

7. Outer Brake Pad

8. Inner Brake Pad

9. Piston Boot (2 plac es)

10. Piston (2 pl aces)

11. Cylinder Seal (2 pl aces )

12. Clip ( 2 places)

Rear Brake Calipe r

Figure 5A - 85

Legend

1. Caliper Housing

2. Bleed Screw

3. Self Locking Bolt (2 places)

4. Guide Pin (2 places)

5. Guide Pin Boot (2 places)

6. Anchor Plate

7. Outer Brake Pad

8. Inner Brake Pad

9. Piston Boot

10. Piston

11. Cylinder Seal

1. Remove guide pin, self locking bolts (3) and

discard.

2. Remove guide pin clips (12) (front brake

caliper only).

3. Separate caliper housing (1) from anchor plat e

(6) and remove brake pads (7 and 8).

4. Withdraw guide pins (4) and boots (5) from

anchor plate (6). Separate boots from pins.

5. 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

progressiv el y incr ea se un til t he p isto n is f orced

out of the bore. This precaution is advisable to

avoid physical injury, as the piston may eject

with considerable force due to the air pressure.

NOTE: As only one piston in the front caliper will

be rem oved b y this m ethod, rem oval of the seco nd

will need to be done by using internal expanding

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

while twisting the piston, apply a pulling force to

remove the piston from its bore.

6. Remove piston boot/s (9) from piston/s (10).

7. Remove cylinder seal (11) from bore, taking

care not to damage bore or seal locating

groove.

8. Remove bleeder screw (2).

Figure 5A - 86

CLEAN AND INSPECT

1. Clean all metal parts t hor o ugh l y with methylate d spirits . Clea n ru bber par ts with brake fluid onl y. Use c le an, 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 F ACTO RS EXIST OR IF T HERE I S ANY DO UBT REG ARDING ITS CONDIT ION. If the bore

is unserviceable, a new housing must be fitted.

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

4. Blow through bleed screw port with compressed air.

REASSEMBLE

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

recommended brake fluid

2. Fit new seal into inner groove of the cylinder

bore. Ensure seal is not twisted and is fully

seated in groo ve.

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

Figure 5A - 87

4. Position each piston (2) into caliper housing

(4), seati ng boot (1) int o gr oove in c aliper bore.

Ensure boot flange is squarely and firmly

seated in groo ve.

5. Push pis ton (2) s qu ar el y int o bor e by hand unt il

fully seated. Ensure piston boot (1) is fully

seated in piston (2) and caliper bore grooves.

Figure 5A - 88

IMPORTANT: To avoid uneven pad wear and/or

noisy brake operation, the assembly of the guide

pins to the caliper housing is critical and the

follo wing MU ST be followed.

6. Lubricate guide pins with silicone type grease

(Dow Corning No. 44 or equivalent).

7. Full y install gu ide pins ( 1) into the anch or plate

(5), without the two boots ( 2).

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

plate (5) and install NEW guide pin bolts (3).

CAUTION: Do not use the original bolts.

9. Us e an open e nd spa nner to hol d the gu ide pin

flat section, then tighten the guide pin bolts (3)

to the correct torque.

#) GUIDE PIN BOLT

TORQUE SPECIFICATION 30 - 34 Nm

IMPORTANT: Check that the caliper housing (4)

and guide pins (1) slide out and in easily from the

anchor plate (5). If any binding is evident, then

steps 6 to 9 must be repeated.

10. Disengage the caliper housing (4) from the

anchor plate( 5) and instal l new guide pin boots

(2) to the guide pins (1).

11. Reassemble caliper housing (4) and anchor

plate (5) together. Squeeze each boot to

remove excess air, then ensure that each

guide pin boot (2) is correctly located in guide

pin and anchor plate grooves.

12. Reinstall bleed screw.

13. Reinstall the brake pads, refer to 2.7 BRAKE

PADS, REPLACE in this Section, for the

correct installation procedure.

Figure 5A - 89

REINST ALL

1. Ensure anchor plate mounting surfaces are clean.

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

3. Position the caliper assembly over the disc and insert the anchor plate reta ining bolts. Tighten the bolts to the

specified torque.

NOTE: New retaining bolts must be used when reinstalling the front brake caliper anchor plate.

!) FRONT BRAKE CALIPER

ANCHOR PLATE BOLT

TORQUE SPECIFICATION 80- 90 Nm, plus

40° - 50°

turn angle

REAR BRAKE CALIPER

ANCHOR PLATE BOLT

TORQUE SPECIFICATION 70 - 100 Nm

4. Reconnect brake hose (1) using NEW, dry, sealing washers (3). Tighten banjo bolt (2) to the correct torque

specification.

BRAKE HOSE TO CALIPER BOLT

TORQUE SPECIFICATION 32 - 37 Nm

NOTE: View A is for the front caliper, while View B is for the rear.

Figure 5A - 90

5. Bleed brake system, refer to 2.4 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.

8. Tighten roa d wheel attachi ng nuts to the specif ied torque a nd in a star pattern. Ref er to 2.1 SERVICE NO TES

AND CAUTIONS, in this S ec tion .

NOTE: Do not use an im pact gun to tighten whee l nuts unless it is fitted with a torque lim iter bar such as T ool No.

AU534 or commercial equivalent. 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 100 - 125 Nm

9. Check level of fluid in master cylinder.

3.4 FRONT BRAKE DISC

LT Section No. – 04-805

REMOVE

IMPORTANT: T he brake disc to hub r elationship 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 wheth er a paint dau b mark ( 1)

is still visible on the brake disc hub surface,

adjacent to one of the wheel studs and in

alignment with the two marks (2) on the end of the

hub, as shown.

If the paint marks are no longer visible, then

carefully mark the relationship of the brake disc to

the hub for reinstallation, using a felt tipped pen or

similar. If this precaution is not taken, then a disc

runout condition could be induced that will cause

brake shudder.

NOTE: If the brak e disc is being rem oved to rectif y

brake shudder, if the brake disc is to be machined

or replaced, or if brake disc to hub matching is not

evident, then the brake disc to the hub must be

indexed. Refer procedure in this Section.

Figure 5A - 91

1. Remove the brake caliper assembly, refer to 3.3 BRAKE CALIPER (FRONT & REAR), in this Sectio n.

NOTE: It is not necess ary to disc onnect the brak e hose from caliper . However, the calip er must be suppor ted with

a wire hook to avoid strain on the brake hose.

2. If neces sary, jar the brak e disc loos e by carefull y tapp i ng the disc in t he c entr e be tween t he whee l s tuds , with a

soft faced hammer (or block of wood and a hard faced hammer), taking care not to damage the wheel stud

threads.

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 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.

NOTE 2: After m achining, the br ake dis c s houl d be

ground to achieve a non-circumferential finish of

0.4 to 2.0 microns.

Figure 5A - 92

NOTE 3: After machining, the chamfer on the

brake disc outer diameter must be 45 deg x 1 mm

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

clearance of 1.3 m m m inimum to 2.5 mm m axim um

(dimension B). This is to prevent thermal stress

cracking at the top of the disc (2).

Figure 5A - 93

NOTE 4: Replace disc if specifications cannot be

achieved above the minimum disc thickness.

CAUTION: Th e Number Cast Into Th e Hub (1) Is

The Minimum Safe Thickness. At This

Thickness The Disc Must Be Replaced

MINIMUM BRAKE DISC THIC KNESS

(REPLACEM ENT REQUIRED) 25. 0 0 mm

Figure 5A - 94

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 mm T otal Indicated Runou t (TIR) and that

the rate of c hang e does no t exc eed 0.03 m m in

30 degrees.

MAXIMUM LATERAL RUNOUT (TIR) 0.04 mm

MAXIMUM LATERAL RUNOUT IN 30 DEG 0.03 mm

IMPORTANT: 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 - 95

3. Check that both sur f ac es of the brak e disc (A &

B) are flat within 0.05 mm TIR.

Figure 5A - 96

4. Check that disc surf aces are paral lel with each

other to within 0.08 mm, when checked

radially.

NOTE: Taper variation must not exceed 0.08mm

Figure 5A - 97

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 degrees as the brake disc is

rotated.

NOTE: To measure the thickness variation,

measure both sides of the brake disc for runout

and add the two measur em ents togeth er.

Example:

Total runout on one side = +0.020 mm

Total runout on other side = - 0.015 mm

Therefore +0.020 +-0.015 = +0.005 mm

Figure 5A - 98

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 max imum runout on the hub with the point of least runout on the brake

disc.

NOTE 2: This procedure is to be used when ever reinstalling brak e discs that have been rem oved f or machining off -

car. It must also be used when installing new brake discs or brake discs that have been removed for any reason

and where the brake disc to hub matching is not evident.

The procedure consists of three parts:

Part 1. Clean mating surfaces

Part 2. Meas ure an d Matc h brak e dis c high point t o hub low p oint. If these m eas urem ents ar e not O K, go to Part

Part 3. Checking hub mounting face runout

Part 1. Clean Mating Surfaces

Ensure tha t brak e disc and hub m ating s urf aces ar e free from dir t, corros ion, etc. If required, use f ine em er y paper

to clean surfaces.

Part 2. Indexing Brake Disc to Hub

1. Install and secure the brake disc onto the hub

with wheel nuts reversed, to avoid damage to

the tapers, and nip up with a spanner.

2. Number each of the wheel stud holes on the

front surface of the brake disc from 1 to 5.

Place a chalk mark on the end of the wheel

stud adjacent to the number “1” hole (arrow).

NOTE: While the rear disc and caliper are

illustrated, the procedure for indexing the front

brake disc to the front hub, is the same.

Figure 5A - 99

3. Set up a dia l indicator on a magnetic b ase and

attach to the strut tube above the brake disc.

Position the pointer about 10 to 15mm inboard

from the outer diameter of the brake disc.

4. Carefully rotate the brake disc and note the

points of minim um and m axim um runout on th e

dial indic ator. T he num ber of divis ions bet ween

these two points is the total indicated runout.

Record this figure toget her with the num ber on

the brake disc aligned with the chalk-marked

stud.

5. Remove and reinstall the brake disc with hole

number “2” over the m arked stud. Rep eat 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.

IMPORTANT: If the lowest assembled disc runout

achieved is more than 0.050 mm (50 micron) then

the hub runout should be checked as detailed in

Part 3 of this procedure.

MAXIMUM ASSEMBLED DISC & HUB

RUNOUT AT DISC OUT ER DI AM ET ER 0.05 mm

Figure 5A - 100

Part 3. Hub Runout Check

1. Clean the front hub face by rubbing lightly with

fine emery paper.

2. Locate the dial indicator on the strut tube and

position the pointer on the hub face about

midway between the spigot and the studs.

NOTE: For this check to be performed to 100 %

accurac y, a f lat para lleled surf ace plat e attac hed 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 s hould

be replaced.

MAXIMUM RUNOUT AT

HU B FAC E – FRONT HUB 0.025 mm

Figure 5A - 101

REINST ALL

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

position.

2. Reinstall the brake caliper assembly, refer to 3.3 BRAKE CALIPER (FRONT & REAR), in this Section.

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

4. Reinstall road wheels aligning marks made prior to removal, loosely reinstall nuts, then lower vehicle.

5. 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 unles s it is fitted with a tor que limiter bar such

as Tool No. AU534 or commercial equivalent.

Failure to c orr ec t l y tighte n whee l n uts to th e c orr ec t

torque specification may result in a warped brake

disc, which may lead to development of brake

shudder.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 100 - 125 Nm

Figure 5A - 102

3.5 REAR BRAKE DISC

LT Section No. – 04-825

REMOVE

IMPORTANT: T he brake disc to hub relati onship is caref ully matched duri ng production (index ed), to m inimise 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 br ake disc is being rem oved to r ectif y brake shudder , if the br ake dis c is to be m achined or replaced,

or if brake disc to hub matching is not evident, the brake disc to the hub must be indexed, as detailed in this

Section.

1. Ensure park brake is fully released.

2. Remove the brake caliper assembly, refer to 3.3 BRAKE CALIPER (FRONT & REAR), in this Section.

NOTE: It is not necessary to disconnect the brake hose from the caliper. However, the caliper must be supported

with a wire hook to avoid strain on brake hose.

3. If neces sary, jar the brak e disc loos e by careful ly tapp i ng the dis c in the centre between the wh ee l st uds, with a

soft faced hammer (or block of wood and a hard faced hammer), taking care not to damage the wheel stud

threads.

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

park brake shoes. Refer to Operation 3.7 PARK BR AKE SHOE, ADJUST, in this Section.

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 or replaced.

NOTE 1: Machine or r es urfac e BO T H sides of dis c.

Do not machine or resurface one side only.

NOTE 2: After mac hining, disc f inish 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

thi ckness.

MINIMUM BRAKE DISC THIC KNESS

(REPLACEM ENT REQUIRED) 13.9 m m

WARNING: THE DISC MUST BE REPLACED AT

THIS THICKNESS!

Inspect brake disc as follows:

1. Check that sur f ac e B is flat with in 0.0 8 m m 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 axl e and tha t rate of change d oes

not exceed 0.03 mm in 30°.

5. Check that maximum circumferential thickness

(also referred to as Disc Thickness Variation

(DT V) does not vary by more than 0 . 01 3 m m at

any radius when disc is rotated.

Figure 5A - 103

BRAKE DISC AND HUB INDEXING PROCEDURE

NOTE 1: Th e brake disc and hub indexing is required in or der to obtain the minimum installed disc runout. Brak e 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: T his procedure is to be used whenever reinstalling brak e discs that have be en rem oved for m achining 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 tha t brak e disc and hub m ating s urf aces ar e free from dir t, corros ion, etc. If required, use f ine em er y paper

to clean surfaces.

Part 2. Indexing Brake Disc to Hub

1. Fasten the brake disc onto the hub with wheel

nuts reversed to avoid damage to the tapers,

and nip up with a spanner.

2. Number each of the wheel stud holes on the

front surface of the brake disc from 1 to 5.

Place a chalk mark on the end of the wheel

stud adjacent to the number “1” hole (bold

arrow).

Figure 5A - 104

3. Set up a dia l indicator on a magnetic b ase and

attach to a pre-fabricated mounting plate (1)

(refer 7. SPECIAL TOOLS in this Section for

pre-fabricated mounting plate details) bolted to

the caliper attaching points. Position the

pointer of the dial indicator about 10 to 15mm

inboard from the outer diameter of the brake

disc.

4. Carefully rotate the brake disc and note the

points of minim um and m axim um runout on th e

dial indic ator. T he num ber of divis ions bet ween

these two points is the total indicated runout.

Record this figure toget her with the num ber 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. T his procedur e is to be repeat ed for 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.

MAXIMUM ASSEM BLED BRAKE DISC &

TRUNNION HUB RUNOUT AT BRAKE DI SC

OUTER DIAM ET ER – REA R B R AKE D ISC 0.08 mm

Figure 5A - 105

Part 3 Trunnion Hub Runout Check

1. Clean the front hub face by rubbing lightly with

fine emery paper.

2. Mount a dial indicator on a pre-fabricated

mounting plate bolted to the caliper mounting

points and position th e pointer on the hub face

as sho wn. Refer to 7. SPECIAL TOOLS in this

Section f or dimens ional details of the mounting

plate.

NOTE: For this check to be 100% accurate, a flat

paralle led surfac e plate attached to the hub s hould

be used, howe ver , measuring runou t between each

of the wheel studs should suffice.

3. Carefully rotate the hu b by the wheel s tuds an d

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 - 106

REINST ALL

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

position.

2. Reinstall the brake caliper assembly, refer to 3.3 BRAKE CALIPER (FRONT & REAR), in this Section.

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

4. Adjust park brake shoe clearance. Refer to 3.7 PARK BRAKE SHOE, ADJUST , in this Section, for details.

5. Reinstall road wheels aligning marks made

prior to removal then lower vehicle.

6. 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 unles s it is fitted with a tor que limiter bar such

as Tool No. AU534 or commercial equivalent.

Failure to c orr ec t l y tighte n whee l n uts to th e c orr ec t

torque specification may result in a warped brake

disc, which may lead to development of brake

shudder.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 100 - 125 Nm

Figure 5A - 107

3.6 PARK BRAKE LINING WEAR, CHECK

1. Remove both rear discs. Refer to 3.5 REAR BR AKE DISC, in this Sec t ion.

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

each lining half, using a vernier caliper or similar.

3. W ear should be even and no thinner than the specified minimum thickness. If the minimum thickness is at or

less than specified, then the linings must be replaced. The drum section of the rear disc may also require

grinding. Re fer 3.5 REAR BR AKE DISC, in this Section for specific detail, regarding grinding operations.

MINIMUM PARKING BRAKE SHOE

LINING THICKNESS 1.5 mm

NOTE: If one park brake shoe requires replacement, then both must be replaced.

4. Reinstall rear discs and adjust the park brake shoe clearances, refer 3.5 REAR BRAKE DISC, REINSTALL

and 3.7 P ARK BR AKE SH OE, ADJUST, both in this Section.

3.7 PARK BRAKE SHOE, ADJUST

1. Using a floor jack under centre of differential

carrier, jack up and support rear of vehicle on

safety stands under rear trailing arms.

2. Remove rear wheel covers (steel wheels) or

wheel nut decorative caps (alloy wheels).

3. Mark relationship of wheels to mounting

flanges.

4. Remove roa d whee l attac h i ng nuts and remove

wheels.

5. Release p ar k br ak e and en sur e that par k br ake

actuator arms have fully retracted.

If necessary, loosen the front park brake cable

adjustment nut (arrow) with a deep socket, to

ensure slack in the park brake rear cables.

Figure 5A - 108

6. Remove rear brake caliper anchor plate to

trailing arm attaching bolts (1) (both sides of

vehicle ), then remove calipers (2) from discs.

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

shock absorber upper mountings. DO NOT

ALLOW CALIPERS TO HANG BY BRAKE

HOSES!

8. Reinstall three wheel nuts, reversed to prevent

damage to the tapers and lightly tighten to

secure the disc in place.

Figure 5A - 109

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

suitable lever such as a screwdriver, tighten

the park brake shoe screw adjuster, until the

disc is locked. Access to the screw adjuster is

through either one of two holes (1) provided in

the disc.

10. Loosen the adjuster 3 – 5 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 - 110

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

TORQUE SPECIFICATION 70 - 100 Nm

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 in a star pattern to the correct torque specification. Refer 2.1 SERVICE

NOTES AND CAUTIONS in this Section for more specific information.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 100 - 125 Nm

16. Refit wheel covers/wheel nut decorative caps.

3.8 PARK BRAKE SHOE

LT Section No. – 04-825

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 decorative wheel nut 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 caliper/s from disc/s.

6. Using tie wir e, secure the caliper s to lo wer end

of shock absorber upper mount ings, as shown.

DO NOT ALLOW CALIPERS TO HANG BY

BRAKE HOSES.

7. Index each disc to a wheel stud using a felt

tipped pen or similar, as indicated by the bold

arrow.

8. Remove brake discs.

NOTE: It may be necessary to loosen the park

brake shoe adjustment, to enable disc removal.

Use a suitable size screwdriver, screw in the

adjuster, using one of the two access holes (1) in

the brake disc.

Figure 5A - 111

9. 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 - 112

10. Us ing a screwing m otion, rotate the park brake

shoe around the trunnion flange to remove it

from the vehicle.

11. Rem ove the park brak e s hoe spring retai ner b y

prising from the rear disc shield, with a

screwdriver or similar lever.

12. If required, the actuator screw adjuster and

pins ca n be rem oved at this point, but th e bod y

and remaining components are not able to be

removed without first removing the rear disc

shield. For this operation, refer to 3.10 REAR

DISC SHIELD, in this Sect ion.

Figure 5A - 113

Techline

REINST ALL

1. Apply Mo lybdenum Disulphide grease to t he adjustin g screw an d pins. Fully win d screw into s leeve and ins tall

into the adjuster body.

2. Install the park brake shoe over the trunnion

flange.

3. W ith one shoe end l ocated on the adj uster pin,

roll the shoe to engage the other end onto the

other pin.

Figure 5A - 114

4. Reinstall park brake shoe retaining spring clip,

by sliding it into place, ensuring that the spring

clip is correctly loc ated by the ta ngs in the rear

brake shield.

Figure 5A - 115

5. Reinstall brake discs, aligning marks made on removal.

6. Adjust park brake shoe to disc clearance. Refer to 3.7 PARK BRAKE SHOE, A DJUST, in this Sec ti on.

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

REAR BRAKE CALIPER

ANCHOR PLATE BOLT

TORQUE SPECIFICATION 70 - 100 Nm

8. Adjust park brake cable, refer to 2.2 PARK BRAKE CABLE, ADJUST in this Section.

9. Reinstall road wheels, aligning marks made prior to removal, install but do not tighten attaching nuts.

10. Remove safety stands and lower vehicle.

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

2.1 SERVICE NOTES AND CAUTIONS, in this Section for more specific information.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 100 - 125 Nm

12. Refit wheel covers/wheel nut decorative caps.

3.9 FRONT DISC BRAKE SHIELD

LT Section No. – 04-805

NOTE: The following fasteners MUST be replaced

!) when performing this operation or they have

micro-encapsulated sealant applied and should be

replaced on reassembly (#

#):

Lower strut to steering knuckle bolts and nuts.

Front brake caliper anchor plate to steering

knuckle attaching bolt

Hub to steering knuckle attaching bolts.

REMOVE

1. Raise front of vehicle and support on safety stands under the front crossmember.

2. Remove front wheel cover (steel wheels) or wheel nut decorative caps (alloy wheels) from side of vehicle

where the shield is to be removed.

3. Mark relationship of wheel to hub disc. Remove road wheel attaching nuts and remove wheel.

4. Rem ove the front brak e caliper anchor p late to

front strut knuckle attaching bolts (1), then

remove caliper (2) from disc.

NOTE: Discar d the front br ake c aliper anchor plate

retaining bolts as they must be replaced on

reassembly.

5. Using tie wire, secure the caliper to lower end

of front suspension coil spring. DO NOT

ALLOW CALIPER TO HANG BY BRAKE

HOSE.

6. For vehicles equipped with ABS or ABS/TCS,

disconnect the wheel speed sensor connector

(5) from the steering knuckle by lifting the

connector locking tab and pulling outward to

remove.

7. 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 FRONT BRAKE DISC in this Section, for

further information.

8. Using a commercially available 10 mm Allen

key socket and a suitable socket bar, loosen

each of the three bolts (4) holding the hub to

the steering knuckle support.

NOTE 1: If the Allen key socket is too long to fit

into the f ront, up per hu b bo lt, then the lower str ut to

steering knuckle nut (and bolt – 3) will need to be

loosened a nd r emoved. Discard t he remov ed bol t

and nut, as they must be replaced on

reassembly.

Figure 5A - 116

NOTE 2: For the front lower hub bolt (4), turn wheel outwards to provide sufficient clearance.

9. To remove hub from knuckle, it may first be necessary to tap the loosened bolts to break the seal. DO NOT

STRIKE THE HUB.

10. Remove the three bolts (4) and then the hub from steering knuckle.

11. Rem ove the three rivets (1) securing shiel d to knuck le, by drilli ng the head from each rivet. Rem ove the shiel d

from the knuckle support.

12. Carefully drill out the rivet remainder from the steering knuckle, using a suitable size drill.

REINST ALL

Installat ion is th e rever s e of the r em oval proc e dur e,

except for the following points:

1. Reinstall the brake shield to the steering

knuckle support, securing with three, common

pop rivets (1), using a commercially 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

surfaces to make sure 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

knuck le interface, will cause water t o be dra wn

into the cavity in the steering knuckle, during

the norm al heating and coo ling c ycle of vehic le

operation.

Figure 5A - 117

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

TORQUE SPECIFICATION 120 – 140 Nm

NOTE: The three hub attaching bolts are micro-encapsulated with thread sealant and are not to be re-used more

than three 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 knuckle, then install the three

hub attaching bolts and tighten to the correct torque specification.

FRONT HUB TO STEERING

KNUCKLE ATTACHING BOLT

TORQUE SPECIFICATION 120 – 140 Nm

7. Reinstall the wheel speed sensor connector, pushing fully home. Check that the locking tang is secure.

ALL VEHICLES:

8. If the lower strut to steering knuckle bolt and nut were removed to gain access to the front, upper hub to

steering knuckle bolt, then both the removed bolt and nut must be replaced with new components and

tightened to the correct torque specification.

!) STEERING KNUCKLE TO STRUT

NUT TORQUE SPECIFICATION

Stage 1 85 Nm

Stage 2 100 Nm

Stage 3 turn through 90°

9. Reinstall the brake disc over the wheel studs in the pre-marked position.

10. Position the caliper assembly over the disc and insert the anchor plate retaining bolts. Tighten the bolts to the

specified torque.

NOTE: New retaining bolts must be used when reinstalling the front brake caliper anchor plate.

!) BRAKE CALIPER ANCHOR

PLATE RETAINING BOLTS

TORQUE SPECIFICATION 80 - 90 Nm,

then turn through

40° - 50°

11. Reinstall road wheel, aligning the marks made prior to removal and secure with the attaching nuts.

12. Remove jack stands and lower vehicle.

13. Tighten road wheel attaching nuts to correct torque specification, working in a star pattern (refer to

2.1 SERVICE NOTES AND CAUTIONS, in this Section).

ROAD WHEEL ATTACHING BOLT

TORQUE SPECIFICATION 100 - 125 Nm

14. Refit wheel cover/centre cap.

3.10 REAR DISC BRAKE SHIELD

LT Section No. – 04-825

NOTE: The following fasteners MUST be replaced

!) when performing this operation :

Lower rear disc brake shield to trailing arm

attaching bo lt

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 wheel nut decorative caps (alloy wheels).

3. Mark relationship of wheel to wheel stud, using a felt tipped pen or similar.

4. Remove road wheel attaching nuts and remove wheel.

5. Release park brake.

6. Thoroughly clean around brake hose to pipe

connection at backing plate. Disconnect brake

pipe (4) from the brake hose (3) at backing

plate bracket (2) and remove brake hose

retaining clip (2).

Figure 5A - 118

7. Remove brake caliper anchor plate to trailing

arm attaching bolts and remove caliper from

disc.

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

the shock abs or ber upper mounting/s. DO NOT

ALLOW THE CALIPER/S TO HANG BY THE

BRAKE HOSE/S.

Figure 5A - 119

9. Index each disc to a wheel stud using a felt

tipped pen or similar, as indicated by the bold

arrow.

10. Remove brake disc/s.

NOTE: It may be necessary to loosen the park

brake shoe adjustment, to enable disc removal.

Use a suitable size screwdriver, screw in the

adjuster, using one of the two access holes (1) in

the brake disc.

11. Disconnect the park brake cable from the

actuator arm. See 2.11 REAR PARK BRAKE

CABLES in this Section, for details.

Figure 5A - 120

12. Remove trailing arm trunnion flange and trunnion as sembly, refer to 3.1 TRAILIN G ARM FLANGE, T RUNNI O N

ASSEMB LY AND/OR W HEEL BEARING , in Section 4B, FIN AL DR IVE AND DRIVE SHAFTS in the MY2003

VY and V2 Series Service Information, for the necessary procedure.

IMPORTANT: Beca use t he r em oval proc edure of th e tr unnion f lange will c ause th e be aring t o be br ine lled, it must

be replaced on reassembly. Also refer to Section 4B, FINAL DRIVE AND DRIVE SHAFTS for the necessary

procedure for this task.

13. Following the removal of the trunnion and bearing assembly, the backing plate will be free to be removed,

together with the parking brake show assembly.

14. Remove park brake shoe assembly. Refer to 3.8 PARK BRAKE SHOE, in t his S ec tion.

15. In order to disassemble the park brake actuator

assem bl y (2, 3 a nd 4) f r om the rear d isc shield,

it will be nec essar y to caref ull y support the dis c

shield to minimise distortion, then press the

actuator ass embl y from the lower ex truded b olt

hole sections of the disc plate.

Figure 5A - 121

REINST ALL

Reinstallation of the rear disc shield is the reverse

to the rem oval pr ocedures, exc ept 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.

Legend:

1. Adjusting Screw

2. Adjusting Ratchet Wheel

3. Actuator Body

4. P arking Brake Actuator Lever

5. Brake Shoe Anchor

6. Washer

7. Pin

8. Ratchet Wheel Spring

Figure 5A - 122

3. Reinstall trunnion to the trailing arm, using a new wheel bearing. For the required procedures refer to

3.1 TRAILING ARM FLANGE, TRUNNION ASSEMBLY AND/OR WHEEL BEARING, in

Section 4B FINAL DRIVE AND DR IVE SH AFTS in th e MY2003 VY an d V2 Ser ies Ser vice Inf orm ation, fo r the

necessary procedure.

4. Reinstall the t wo upper rear disc brake shield t o trailing arm attaching Torx bit h eaded bolts. Do not tighten at

this stage.

5. Install two new lower rear disc brake shield to trailing arm bolts.

6. Tighten the four rear disc brake shield to trailing arm attaching bolts to the correct torque specification

UPPER REAR DISC BRAKE SHIELD

TO TRAILING ARM ATTACHING BOLT

TORQUE SPECIFICATION 70 - 80 Nm

(!)_LOWER REAR DISC BRAKE SHIELD

TO TRAILING ARM ATTACHING BOLT

TORQUE SPECIFICATION 70 - 80 Nm

7. Reinstall the park brake shoe. Refer to 3.8 PARK BRAKE SHOE, in this Section.

8. Reinstall the rear disc, aligning the marks made before removal and adjust the park brake shoe, following the

procedure det ai led in 3.7 PARK BRAKE SHOE, ADJUST, in this Section.

9. Install and tighten brake caliper anchor plate to trailing arm attaching bolts to the correct torque specification.

BRAKE CALIPER ANCHOR PLATE

TO TRAILI NG ARM ATTACHI NG

BOLT TORQUE SPECIFICATION 70 - 100 Nm

10. Reinstall the caliper hose (3) to the backing

plate bracket (2) and secure with the retaining

clip (1).

11. Reinstall the brake pipe (4) to the caliper hose

(3) and tighten to the correct torque

specifications.

BRAKE PIPE FLARE NUT TO

CALIPER BRAKE HOSE

TORQUE SPECIFICATION 14 – 17 Nm

12. Reinstall road wheel, aligning marks made

prior to removal and reinstall road wheel

attaching nuts .

13. Remove jack stands and lower vehicle to the

ground.

14. Tighten road wheel attaching nuts to the

specified torque, working in a star pattern.

Refer to 2.1 SERVICE NOTES AND

CAUTIONS, in this Section.

15. Check for brake fluid leaks, repair as

necessary.

Figure 5A - 123

4. DIAG NOSIS

SYMPTOM

X - Indicates Probable Cause

XX - Indicates a More Possible Cause

CAUSE

Excessive Brake Pedal Travel

Brake Pedal Travel Gradually Increases

Excessive Brake Pedal Effort

Excessive Braking Action

Brakes Slow t o Respond

Brakes Slow to Release

Brakes Drag

Uneven Braking Action (Side to Side)

Uneven Braking Action (Front t o Rear)

Scraping Noise from Brakes

Brakes Squeak During Application

Brakes Squeal During a Stop

Brakes Chatter

Brakes Groan at End of Stop

Brake Tell-tal e Lamp Glows During a Stop

Leaking Brake Line or Connection X X X

Leaking Caliper or Pist on Line X X X X X

Leaking Mast er Cylinder X XX X

Air in Brake System XX X X

Contaminated or Improper Brak e Fluid X X X X

Leaking Vacuum System XX X

Restricted Air Passage in Vacuum Booster X XXX

Damaged Vacuu m Booster X X X X XX

Improperly Assembled Vacuum Booster Valving X X X X XX

Worn Out Disc Pads - Replace X X X X X X X X

Uneven Disc Pad Wear - Replace or Correct X X X X X XX X

Contaminat ed Disc Pad - Replace XX XX XX X X X X

Heat Spotted or Scored Brake Discs X XX XX XXX

Out-of-Paral l el Brake Discs XX

Excessive Brake Disc Run-Out X

Brake Assem bly Attachm ents - Missing or Loos e X X X X X X X X

Restrict ed Brak e Fluid Passage or Sticki ng Caliper P iston X X X X X X X

Brake Pedal/Linkage Binding or Interference X X X XX

Improperly Adj usted Parking Brake X

Incorrect Front Wheel Ali gnment X XX

Incorrect Tyre Pressures XX

Wheel Bearing Clearance Excessive X X

Loose Front Suspension and/or Components X XX X X

Out-of-Balance Wheel Assemblies XX

Operator Riding Brake Pedal X X X X X X

Table 1

5. SPECIFICATIONS

BRAKE FLUID

Type ......................................................................... Super DOT 4 Plus

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 cylinder end plug)

FRONT DISC

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

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

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

Lateral Runout (maximu m) ..................................... 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)

Front Disc Pad

Material.................................................................... Organic, non-asbestos

Minimum Thickness before Replacement............... 2 mm

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

Rear Disc Pad

Material.................................................................... Organic, non-asbestos

Minimum Thickness before Replacement............... 2 mm

DRUM PARK BRAKE

Make ......................................................................... PBR

Type ......................................................................... Banksia, single shoe, cable and lever operated

Drum

Inside Diameter (nominal)....................................... 190 mm

Maximu m out of square (TIR with disc surface) ..... 0.05 mm

Maximum out of round ............................................ 0.08 mm

Linings

Type ........................................................................ Bonded

Width....................................................................... 25 mm

Thickness................................................................ 3.5 mm

Minimum Thickness before Replacement............... 1.5 mm

6. TORQUE WRENCH SPECIFI CATIONS

Brake booster retaining nut........................................................ 20 – 25

# Brake caliper guide pin bolt ....................................................... 30 – 34

Brake pressure differential warning switch................................ 2.0

Brake hose to caliper bolt (Front and Rear) .............................. 32 – 37

Brake pedal support shaft nut ................................................... 50 – 60

Brake pipe to brake hose flared nut (All positions).................... 14 – 17

Brake pipe to load sensing proportioning valve (Utility) ............ 11 – 16

Brake pipe to master cylinder flare nut...................................... 8 – 11

! Front brake caliper anchor bolt.................................................. 80 – 90 Nm, plus

40° – 50° turn angle

Front brake pipe clamp to dash panel bolt ................................ 6 - 14

Front hub to steering knuckle bolt.............................................. 120 – 140

Load sensing proportioning valve mounting bracket

Bolt (Utility) ........................................................................... 35 – 60

Load sensing proportioning valve mounting nut (Utility)............ 35 – 40

Lower brake pipe shield to floor bolt.......................................... 6 - 14

Lower brake pipe shield to floor nut........................................... 1.5 - 3

Master cylinder attaching nut..................................................... 15 – 20

Master cylinder to bracket bolt and bracket to tower nut........... 15 – 22

Master cylinder end pl ug............................................................ 25 – 30

Master cylinder reservoir retaining screw.................................. 4.0 – 5.0

Outer front park brake cable bracket retaining bolt ................... 20 – 25

Park brake lever bolt.................................................................. 35 – 65

Rear brake caliper anchor plate bolt.......................................... 70 – 100

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

! Rear disc brake shield to trailing arm Lower bolt..................... 85 – 90

Road wheel attach in g nut.......................................................... 100 – 125

! Steering knuckle to strut attaching bolts and nuts Stage 1 .... 85

Stage 2 .... 100

Stage 3 .... Turn through 90°

Throttle pedal support attaching nut.......................................... 20 – 25

! Fastener/s must be replaced on reassembly.

# Fastener/s have micro-encapsulated sealant applied and should be replaced on

reassembly.

7. SPECIAL TOOLS

TOOL NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

AU533

QUICK CONNECT FITTING

RELEASE TOOL

Released in two sizes;

Red for 5/16” fitti ngs and

Blue for 3/8” fittings.

Also available commercially under P/N

Essential

AU534

TORQUE LIMITING SOCKET

Used in conjunction with an impact

gun to tighten wheel nuts.

Essential

E7115

ANGLE WRENCH

1. Previously released for J and V

cars, as Tool No. 394.

2. Used to tighten component f ast eners

when angle torque is required.

Available

J23738-A

HAND VACUUM PUMP Mandatory

DIAL INDICAT OR PLAT E

Dealer fabric ated:

1. Fabricat ed from 6mm thick Mild Steel Plate.

2. If using the cali per bolts to attac h the plate to the trunnion, a 17mm

spacer will need to be installed on each bolt, prior to installing.