206-03b FPV PERFORMANCE FRONT DISC BRAKE 206-03b

SECTION : 206-03B FPV PERFORMANCE FRONT

DISC BRAKE
VEHICLE APPLICATION : 2006.0 FPV GT/GT-P, Pursuit, Super Pursuit, F6
Typhoon and F6 Tornado
CONTENTS PAGE
SPECIFICATIONS
General Information .............................................................................................................206-03B-1
General Specifications .........................................................................................................206-03B-1
Torque Specifications ..........................................................................................................206-03B-1
DIAGNOSIS AND TESTING
Front Disc Brake ..................................................................................................................206-03B-2
REMOVAL AND INSTALLATION
Brake Pads ..........................................................................................................................206-03B-3
Front Brake Hose ................................................................................................................206-03B-5
Brake Caliper .......................................................................................................................206-03B-6
Brake Disc ...........................................................................................................................206-03B-7

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SPECIFICATIONS

GENERAL INFORMATION
The FPV Performance brake package described in
this Section is standard equipment on FPV GT, F6
Tornado, Pursuit Ute, and F6 Typhoon. See Section
206-03C for information on the FPV Premium brake
system, fitted standard to GT-P and Super Pursuit
and optional on all other FPV variants.
General Specifications
Description Specification
Minimum brake disc 30 mm
thickness(discard
thickness)
Fluid
High performance ESZ-M6C55-A
SUPER DOT 4 brake
fluid
Lubricants
High melting point Molykote CU-7439+
grease (supplied in pad kit).
Pad
Material Textar T4000
Lining wear limit 7.5 mm measured from the
back of the pad backing
shim
Torque Specifications
Description Nm
Brake hose to caliper 23 - 26
Caliper bleed valves 12 - 16
Brake caliper bolts (fixing caliper to 105 - 125
bracket)
Brake caliper assembly to spindle 105 - 125

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DIAGNOSIS AND TESTING

Front Disc Brake

Refer to Section 206-00B FPV Performance Brake
System, General Information.

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REMOVAL AND INSTALLATION

Brake Pads 3. Remove safety split pins, using a pair of pliers.

Removal
WARNING: Although original equipment pad
material is asbestos free. If non genuine pads are
used, the following applies:
1. Asbestos fiber dust may be present on brake
and clutch assemblies and is hazardous to health
if inhaled.
2. Brake and clutch assemblies should be cleaned
using a vacuum cleaner recommended for use
with asbestos fibers such as a
brake/clutch/service vacuum. The bag must be
labeled per OSHA instructions, sealed, and the
trash hauler notified as to the bag’s contents.
4. Using a hammer and pin driver, drive out one pin
3. If the vacuum suitable for asbestos is not far enough to remove, keeping the spring in
available, cleaning should be done wet. If dust position with one hand.
generation is still possible, technicians should
wear government-approved toxic dust purifying
respirators. Failure to follow these instructions
may result in personal injury.
1. Clean and remove master cylinder reservoir cap.
Loosen front brake line connection at the master
cylinder, allowing fluid to bleed into a container
until master cylinder reservoir is one-third full. Re
tighten line connection and replace master
cylinder cap.
WARNING: Brake fluid will damage
paintwork.
NOTE: Do not completely remove brake line or
empty the reservoir or it will be necessary to
bleed the system. 5. Remove the spring and remaining pin.
NOTE: Discard the fluid removed. DO NOT CAUTION: Perform the steps described
RE-USE. below with caution. The retraction of pistons
NOTE: Removal of the fluid is necessary to can cause brake fluid to spurt from the tank. If
prevent reservoir overflow when the caliper the fluid comes in contact with painted parts it
pistons are pushed back into the calliper bores will damage them. Make sure the level of fluid
during pad replacement. in the tank is moderate, draining some fluid if
necessary.
2. With vehicle raised evenly on a hoist or jack
stands, mark relationship of each wheel to its hub
and remove the front wheels.
Using wheel nuts, secure disc to hub during work.
NOTE: If more than one brake requires service,
work on only one brake at a time. Pad
assemblies, must be always replaced in both
brakes.

CAUTION: DO NOT disconnect the brake fluid

pipe from the caliper while performing any of the
steps described below.

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REMOVAL AND INSTALLATION (Continued)

6. Carefully move the pistons back with a retractor or 10. Clean the braking area of the disc using
another suitable tool by applying pressure to the degreasing products.
worn pads.

Installation
7. Remove the worn pads. 1. Apply grease supplied in replacement brake pad
kit to the metal sides of each pad.
CAUTION: Apply grease only to the metal
sides of each pad.
WARNING: Make sure that no grease
remains on the braking surface of the pad. If
grease does contact this surface, clean it off
completely with sandpaper.

8. Clean the piston faces and pad abutment shims

using a damp cloth.
CAUTION: Do not use products that could
damage the gaskets, such as nitro-perchlor
thinner, gasoline, trichloroe-thylene, or other
such mineral solvents.

2. Place one of the pins in the correct position in the

caliper and pad, then insert it completely using a
hammer and pin driver.

9. Check piston dust covers for damage.

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REMOVAL AND INSTALLATION (Continued)

3. Re-fit the spring. Then re-fit the second pin while Front Brake Hose
exerting pressure on the spring with one hand and
pushing the pin in as far as it will go using a Removal
hammer and pin driver. Check correct positioning
of the spring.
CAUTION: Make sure that the spring is
correctly installed.

4. Install safety split pins.
5. Re-install the wheels and torque wheel nuts to
specification.
6. Operate the brake pedal until optimum pressure is
restored to the system.
7. Check the level of the brake fluid in the reservoir,
and replenish if necessary.
8. Run in the pads for 100 to 200 kilometers making
several light stops. Avoid heavy braking or
braking from high speeds.
CAUTION: After installing new pads,
braking effectiveness may be reduced during
the first brake applications. Therefore, reduce
speed and avoid sudden, continuous, or
excessive braking.
Item Description
1 Clip
2 Brake tube connector
3 Banjo bolt
4 Grommet
5 Hose positioning bracket
1. Remove banjo bolt and washers (3).
2. Remove grommet from hose positioning bracket
(5).
3. Disconnect the brake tube connector (2).
4. Remove clip (1).
5. Remove hose assembly.
Installation
1. Install banjo bolt (3) and new washers. Torque to
specification.
2. Install grommet into hose positioning bracket (5).
3. Install hose into body bracket and install clip (1).
NOTE: Ensure hose is engaged to bracket prior to
fitment of banjo bolt. Check routing for correct
clearance on completion.
4. Connect brake tube and torque to specification.
5. Bleed as outlined in procedure in Brake Caliper
section below.

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REMOVAL AND INSTALLATION (Continued)

Brake Caliper 2. Clean the braking area of the disc with a

degreasing product.
Removal
1. Raise and support the vehicle to ensure it is
stable and secure. Mark the relationship of the
wheel and the rotor and remove wheel.
2. Remove the pads from the caliper to be replaced.
Follow the brake pad removal procedure
mentioned above.
3. Using a felt pen, mark the disc rotation direction
on the pads to ensure that they are positioned
correctly during refitting.
4. Loosen the brake fluid pipe on the caliper enough
to permit complete unscrewing by hand, but tight
enough to prevent leakage of brake fluid. Then
proceed to:
3. Position the new caliper on the spindle, install
Place a drain tray beneath caliper assembly.
mounting bolts and torque to specification.
Completely detach the brake fluid supply pipe
from the caliper. Plug caliper inlet port.
Unscrew the caliper fixing bolts with a socket
and wrench and remove the caliper from the
spindle.
CAUTION: During all the phases
described below, ensure that the brake
fluid does not come into contact with parts
of the vehicle that could be damaged, in
particular the painted parts.
Immediately stop any leak with paper and
clean up with water in the event of splashes
or accidental fluid leaks.

4. Re-connect the brake fluid supply pipe and torque

to specification.
NOTE: Each caliper has two (2) brake bleeder
screws; one to bleed the inner caliper pistons
(suspension side) and the other to bleed the outer
(wheel side) caliper pistons. Always commence
bleeding via the outer bleeder screw.

5. Remove the caliper to be replaced.

Installation
1. Install pads as per procedure above.

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REMOVAL AND INSTALLATION (Continued)
5. Fit a clear plastic tube to the outer brake bleeder 11. With the engine running, apply a strong pressure
screw and place a container at the end of the pipe
to collect displaced fluid.
6. Open the bleeder screw and repeatedly operate
the brake pedal in the vehicle until brake fluid
begins to come out of the bleed plug.
CAUTION: Throughout the bleeding
procedure, continually monitor the level of
brake fluid in the brake master cylinder
reservoir, to ensure that an adequate fluid
level is maintained.
7. Tighten the bleeder screw and torque as
specified.
8. Wait a few seconds and then repeat the bleeding
procedure until fluid comes out without any air
bubbles and until the normal resistance and
stroke of the brake pedal are restored.
9. Tighten the bleeder screw, torque as specified
and remove the clear plastic tube from the
bleeder screw.
10. Repeat the above bleeding procedure for the
inner bleeder screw.
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206-03b-7
on the brake pedal and check that there are no
fluid leaks from the caliper, no abnormal drop in
line pressure of the circuit and that the rear brake
lights come on.
WARNING: If there are fluid leaks from
the caliper, repeat all the above operations to
ascertain the cause and correct the fault.
12. Refit the wheels and torque wheel nuts to
specification.
Brake Disc
Removal
1. Remove the wheels.
2. Remove the caliper assembly from the spindle
and the disc, as previously described in this
section. If the caliper does not require servicing, it
is not necessary to disconnect the brake hose.
Position the caliper out of the way, and support it
with a wire to avoid damaging the caliper or the
hose. Handle the disc, linings and caliper
assemblies carefully to avoid deformation, nicking,
scratching or contamination.
3. Remove the disc from hub.
Installation
1. Position the disc on the axle flange.
NOTE: Ensure that all mounting surfaces are
clean and free from contamination which could
cause possible disc runout.
2. Mount the caliper assembly on the spindle
following the Disc Brake Caliper Assembly
Installation procedure in this section.
3. Install the wheel and torque wheel nuts to
specification.