Peugeot 405. Manual - part 43

that it contacts the handbrake operating
lever on the trailing brake shoe. Push the
lever until the stop-peg slips behind the
brake shoe web, allowing the brake shoes
to retract fully (see illustrations). The
brake drum can now be withdrawn.

Inspection

Note: If either drum requires renewal, BOTH
should be renewed at the same time, to
ensure even and consistent braking. New
brake shoes should also be fitted.
4 Working carefully, remove all traces of
brake dust from the drum, but avoid inhaling
the dust, as it is injurious to health.
5 Clean the outside of the drum, and check it
for obvious signs of wear or damage, such as
cracks around the roadwheel bolt holes;
renew the drum if necessary.
6 Examine carefully the inside of the drum.
Light scoring of the friction surface is normal,
but if heavy scoring is found, the drum must
be renewed. It is usual to find a lip on the
drum’s inboard edge which consists of a
mixture of rust and brake dust; this should be
scraped away, to leave a smooth surface
which can be polished with fine (120- to 150-
grade) emery paper. If, however, the lip is due
to the friction surface being recessed by
excessive wear, then the drum must be
renewed.
7 If the drum is thought to be excessively
worn, or oval, its internal diameter must be
measured at several points using an internal

micrometer. Take measurements in pairs, the
second at right-angles to the first, and
compare the two, to check for signs of ovality.
Provided that it does not enlarge the drum to
beyond the specified maximum diameter, it
may be possible to have the drum refinished
by skimming or grinding; if this is not possible,
the drums on both sides must be renewed.
Note that if the drum is to be skimmed, BOTH
drums must be refinished, to maintain a
consistent internal diameter on both sides.

Refitting

8 If a new brake drum is to be installed, use a
suitable solvent to remove any preservative
coating that may have been applied to its
interior. Note that it may also be necessary to
shorten the adjuster strut length, by rotating
the strut wheel, to allow the drum to pass over
the brake shoes.
9 Ensure that the handbrake lever stop-peg is
correctly repositioned against the edge of the
brake shoe web (see illustration), and ensure
that the mating faces of the hub and brake
drum are clean, then slide the brake drum
onto the hub.
10 Refit and tighten the drum retaining
screw.
11 Depress the footbrake several times to
operate the self-adjusting mechanism.
12 Repeat the above procedure on the
remaining rear brake assembly (where
necessary), then check and, if necessary,
adjust the handbrake cable as described in
Section 17.
13 On completion, refit the roadwheel(s),
then lower the vehicle to the ground and
tighten the wheel bolts to the specified
torque.

10 Front brake caliper - removal,

overhaul and refitting

Bendix caliper

Removal

1 Apply the handbrake, then jack up the front
of the vehicle and support it on axle stands
(see “Jacking and Vehicle Support”). Remove
the appropriate roadwheel.
2 Minimise fluid loss by first removing the
master cylinder reservoir cap, and then
tightening it down onto a piece of polythene,
to obtain an airtight seal. Alternatively, use a
brake hose clamp, a G-clamp or a similar tool
to clamp the flexible hose (see illustration).
3 Remove the brake pads as described in
Section 4.
4 Clean the area around the union, then
loosen the fluid hose union nut.
5 Slacken the two bolts securing the caliper
assembly to the hub carrier and remove them
along with the mounting plate, noting which
way around the plate is fitted. Lift the caliper
assembly away from the brake disc, and
unscrew it from the end of the fluid hose. Plug
the open ends of the caliper and hose to
prevent dirt ingress and fluid loss.

Overhaul

6 The caliper can be overhauled after
obtaining the relevant repair kit from a
Peugeot dealer. Ensure that the correct repair
kit is obtained for the caliper being worked on.
Note the locations of all components to
ensure correct refitting, and lubricate the new
seals using clean brake fluid. Follow the
assembly instructions supplied with the repair
kit (see illustration).

Braking system 9•11

9.9 Check that the handbrake lever stop-

peg (arrowed) is against the shoe edge

E Handbrake operating lever stop-peg location

10.2 Using a clamp on the caliper

hydraulic hose

9.3b Releasing the handbrake

operating lever

9.3a Using a screwdriver inserted through

the brake drum to release the handbrake

operating lever

Refitting

7 Screw the caliper fully onto the flexible hose
union, then position the caliper over the brake
disc.
8 Clean the threads of the caliper mounting
bolts, and apply a suitable locking compound
to them. Refit the bolts along with the
mounting plate, ensuring that the plate is
fitted so that its bend curves away from the
caliper body. With the plate correctly
positioned, tighten the caliper bolts to the
specified torque.
9 Securely tighten the brake hose union nut,
then refit the brake pads as described in
Section 4.
10 Remove the brake hose clamp or
polythene, as applicable, and bleed the
hydraulic system as described in Section 2.
Note that, providing the precautions
described were taken to minimise brake fluid
loss, it should only be necessary to bleed the
relevant front brake.
11 Refit the roadwheel, then lower the
vehicle to the ground and tighten the
roadwheel bolts to the specified torque.

Girling caliper

Removal

Note: New guide pin bolts must be used on
refitting.
12 Proceed as described in paragraphs 1 to 4.
13 Where applicable, remove the dust cover,
then slacken and remove the upper caliper
guide pin bolt, using a slim open-ended
spanner to prevent the guide pin itself from
rotating (see illustration). Discard the guide
pin bolt - a new bolt must be used on refitting.
Lift the caliper away from the disc, and
unscrew it from the end of the fluid hose. Plug
the open ends of the caliper and hose to
prevent dirt ingress and fluid loss.

Overhaul

14 Proceed as described in paragraph 6 (see
illustration).

Refitting

15 Screw the caliper body fully onto the
flexible hose union.
16 If the threads of the new guide pin bolts
are not already pre-coated with locking
compound, apply a suitable locking
compound to them.

9•12 Braking system

10.13 Removing a Girling caliper upper

guide pin bolt

1 Guide bolt
2 Caliper body
3 Pad retaining plate kit
4 Bleed screw
5 Mounting plate
6 Guide pin assembly
7 Repair kit

10.6 Components of

Bendix front caliper

10.14 Components of Girling

front caliper

1 Mounting bracket bolt
2 Bleed screw
3 Caliper body
4 Mounting bracket
5 Guide pin assembly
6 Repair kit

17 Manoeuvre the caliper into position, and
fit the new upper guide pin bolt. Tighten the
guide pin bolt to the specified torque, while
retaining the guide pin with an open-ended
spanner. Where applicable, refit the dust
cover to the guide pin bolt.
18 Proceed as described in paragraphs 9
to 11.

11 Rear brake caliper - removal,

overhaul and refitting

Note: Before starting work, refer to the note at
the beginning of Section 2 concerning the
dangers of hydraulic fluid, and to the warning
at the beginning of Section 4 concerning the
dangers of asbestos dust.
Note: New caliper guide pin bolts must be
used on refitting.
Note: To avoid the requirement to pre-bleed
the caliper before refitting, unless the unit is to
be overhauled, do not drain the hydraulic fluid
from the caliper - plug the fluid port in the
caliper to prevent fluid loss. Peugeot parts
dealers will supply new calipers filled with
brake fluid.

Removal

1 Chock the front wheels, then jack up the
rear of the vehicle and support it on axle
stands (see “Jacking and Vehicle Support”).
Remove the appropriate roadwheel.
2 Minimise fluid loss by first removing the
master cylinder reservoir cap, and then
tightening it down onto a piece of polythene,
to obtain an airtight seal. Alternatively, use a
brake hose clamp, a G-clamp or a similar tool
to clamp the flexible hose.
3 Remove the brake pads (see Section 5).
4 Clean the area around the union, then
loosen the fluid hose union nut.
5 Where applicable, prise off the dust cover,
then slacken and remove the lower caliper
guide pin bolt, using a slim open-ended
spanner to prevent the guide pin itself from
rotating. Discard the guide pin bolt - a new
bolt must be used on refitting. Lift the caliper
away from the disc, and unscrew it from the
end of the fluid hose. Plug the open ends of
the caliper and hose to prevent dirt ingress
and fluid loss.

Overhaul

6 The caliper can be overhauled after
obtaining the relevant repair kit from a

Peugeot dealer. Ensure that the correct repair
kit is obtained for the caliper being worked on.
Note the locations of all components to
ensure correct refitting, and lubricate the new
seals using clean brake fluid. Follow the
assembly instructions supplied with the repair
kit (see illustration).

Caliper pre-bleeding

Note: This operation must be carried out
whenever the caliper has been overhauled or
drained of its fluid, and the operation must be
carried out with the caliper removed.
7 With the rear of the vehicle supported on
axle stands, and the relevant roadwheel
removed, proceed as follows.
8 Reconnect the fluid hose to the caliper, and
tighten the union nut.
9 Place a trolley jack beneath the right-hand
rear suspension trailing arm, and raise the arm
to actuate the rear brake pressure regulating
valve (see Section 21).
10 Position the caliper vertically, with the
bleed screw uppermost, and keep it in this
position throughout the following bleeding
operation.

11 Place a block of wood approximately 20.0
mm thick between the caliper piston and the
caliper body (ie, in the position normally
occupied by the brake pads) to prevent the
piston from being ejected.
12 Remove the brake hose clamp or
polythene, as applicable, then connect a hose
and bottle to the bleed screw, and bleed the
caliper using one of the methods described in
Section 3 (note that Peugeot recommend that
pressure bleeding equipment is used). When
the fluid emerging is free from air bubbles,
tighten the bleed screw (see illustration).
13 Continue to pressurise the hydraulic

Braking system 9•13

11.12 Rear caliper ready for pre-bleeding

1 Bleed screw 2 Wooden block

1 Mounting bracket bolt
2 Bleed screw
3 Handbrake lever spring

4 Caliper body
5 Mounting bracket
6 Guide pin assembly

7 Repair kit

11.6 Components of rear caliper

Rest the caliper on a block
of wood under the vehicle.

system (eg, by “pumping” the brake pedal)
until the caliper piston contacts the block of
wood.
14 Open the caliper bleed screw, and remove
the block of wood from the caliper.
15 Push the caliper piston fully into the
caliper bore. Retract the caliper piston by
applying pressure, and turning it clockwise. A
special tool is available for this purpose but a
pair of circlip pliers or any similar tool can be
used instead. Take care not to damage the
surface of the piston. Turn the piston to
position the notches in the piston on the
centreline of the slot in the front of the caliper.
16 Tighten the bleed screw.
17 Refit the block of wood to the caliper,
then repeat the procedure described in
paragraphs 12 to 17 inclusive.
18 On completion, ensure that the bleed
screw is tightened, then disconnect the bleed
hose.
19 Lower the trailing arm and remove the
trolley jack, then refit the caliper as follows.

Refitting

Note: Provided that the caliper has not been
drained of its fluid, the unit can be refitted as
follows. If the caliper has been overhauled or
drained for any reason, the pre-bleeding
procedure described in the preceding
paragraphs must be carried out before
refitting.
20 Screw the caliper body fully onto the
flexible hose union (if not already done).
21 If the threads of the new guide pin bolts
are not already pre-coated with locking
compound, apply a suitable locking
compound to them.
22 Manoeuvre the caliper into position, and
fit the new lower guide pin bolt. Tighten the
guide pin bolt to the specified torque, while
retaining the guide pin with an open-ended
spanner. Where applicable, refit the dust
cover to the guide pin bolt.
23 Securely tighten the brake hose union nut
(if not already done), then refit the brake pads
as described in Section 5.
24 Remove the brake hose clamp or
polythene, as applicable, and bleed the
hydraulic system as described in Section 2 (if
not already done). Note that, providing the
precautions described were taken to minimise
brake fluid loss, it should only be necessary to
bleed the relevant rear brake.
25 Refit the roadwheel, then lower the
vehicle to the ground and tighten the
roadwheel bolts to the specified torque.

12 Rear wheel cylinder -

removal, overhaul and refitting

Removal

1 Remove the brake drum (see Section 9).
2 Using pliers, carefully unhook the upper
brake shoe return spring, and remove it from
both brake shoes. Pull the upper ends of the
shoes away from the wheel cylinder to
disengage them from the pistons.
3 Minimise fluid loss by first removing the
master cylinder reservoir cap, and then
tightening it down onto a piece of polythene,
to obtain an airtight seal. Alternatively, use a
brake hose clamp, a G-clamp or a similar tool
to clamp the flexible hose at the nearest
convenient point to the wheel cylinder.
4 Wipe away all traces of dirt around the
brake pipe union at the rear of the wheel
cylinder, and unscrew the union nut (see
illustration). Carefully ease the pipe out of the
wheel cylinder, and plug or tape over its end
to prevent dirt entry. Wipe off any spilt fluid
immediately.
5 Unscrew the two wheel cylinder retaining
bolts from the rear of the backplate, and
remove the cylinder, taking great care not to
allow surplus hydraulic fluid to contaminate
the brake shoe linings.

Overhaul

Models without underbody-mounted
rear brake pressure-regulating valve
(see Section 21)

6 It is not possible to overhaul the cylinder,
since no components are available separately.
If faulty, the complete wheel cylinder
assembly must be renewed.

Models with underbody-mounted rear
brake pressure-regulating valve (see
Section 21)

7 The wheel cylinder can be overhauled after
obtaining the relevant repair kit from a
Peugeot dealer. Ensure that the correct repair
kit is obtained for the wheel cylinder being
worked on. Note the locations of all
components to ensure correct refitting, and
lubricate the new seals using clean brake
fluid. Follow the assembly instructions
supplied with the repair kit (see illustrations).

Refitting

8 Ensure that the backplate and wheel
cylinder mating surfaces are clean, then

spread the brake shoes and manoeuvre the
wheel cylinder into position.
9 Engage the brake pipe, and screw in the
union nut two or three turns to ensure that the
thread has started.
10 Insert the two wheel cylinder retaining
bolts, and tighten them securely. Now fully
tighten the brake pipe union nut.
11 Remove the clamp from the flexible brake
hose, or the polythene from the master
cylinder reservoir (as applicable).
12 Ensure that the brake shoes are correctly
located in the cylinder pistons, then carefully
refit the brake shoe upper return spring, using
a screwdriver to stretch the spring into
position.
13 Refit the brake drum (see Section 9).
14 Bleed the brake hydraulic system (see
Section 2). Providing precautions were taken
to minimise loss of fluid, it should only be
necessary to bleed the relevant rear brake.

9•14 Braking system

12.4 Brake pipe union (A) and rear wheel

cylinder retaining bolts (B)

12.7b Bendix rear wheel cylinder

components - models with underbody-

mounted brake pressure-regulating valve

1 Cylinder
2 Securing bolt

3 Bleed screw
4 Repair kit items

12.7a Girling rear wheel cylinder

components - models with underbody-

mounted brake pressure-regulating valve

A Repair kit items

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