Peugeot 405. Manual - part 44

13 Master cylinder - removal,

overhaul and refitting

3

Removal

1 Disconnect the battery negative lead.
2 Remove the cap from the brake fluid
reservoir, place a piece of polythene sheet
over the filler neck, and refit the cap tightly.
Alternatively, siphon all the fluid from the
reservoir using an old teat pipette or poultry
baster. This will minimise fluid loss during the
following procedure.

3 To improve the clearance available for
removal, remove the windscreen wiper arms
(see Chapter 12), then remove the scuttle
cover panel from the front edge of the
windscreen (see Chapter 11).
4 Disconnect the wiring from the low brake
fluid level warning sensor.
5 Unscrew the two nuts securing the master
cylinder to the brake vacuum servo unit (see
illustration).
6 Unscrew the union nuts, and disconnect
the brake fluid pipes from the master cylinder.
7 Lift the master cylinder, complete with the fluid
reservoir, from the servo unit (see illustration).
Hold a cloth under the assembly to catch any
fluid spillage. Recover the sealing ring.
8 Unscrew the clamp nut and bolt, release
the plastic clamp, and withdraw the fluid
reservoir from the master cylinder.

Overhaul

9 No spare parts are available from Peugeot
for the master cylinder, and if faulty the
complete unit must be renewed.

Refitting

10 Refitting is a reversal of removal, bearing
in mind the following points.

a) Examine the master cylinder sealing ring

and renew if necessary.

b) Ensure that the brake pipe union nuts are

securely tightened.

c) Refit the windscreen wiper arms with

reference to Chapter 12.

d) On completion, remove the polythene,

where applicable, then top-up and bleed
the hydraulic system as described in
Section 2.

14 Brake pedal - 

removal and refitting

4

Note: On models fitted with the Bendix
“integral” ABS, the hydraulic modulator unit
must be removed in order to remove the brake
pedal. This task must be entrusted to a
Peugeot dealer - see Section 23.

Removal

1 The pedal assembly is removed complete
with the vacuum servo, and the procedure is
described in Section 15.
2 With the servo/pedal assembly removed,
proceed as follows.
3 Remove the securing clip, and withdraw the
pin securing the servo pushrod to the pedal.
4 Unscrew the nut from the pedal pivot bolt,
and withdraw the pivot bolt to release the
pedals (see illustration).

Refitting

5 Refitting is a reversal of removal, but renew
the nylon pedal pivot bushes if they are worn,
and refit the servo/pedal assembly as
described in Section 15.

15 Vacuum servo unit - testing,

removal and refitting

4

Testing

1 To test the operation of the servo unit,
depress the footbrake several times to
exhaust the vacuum, then start the engine
whilst keeping the pedal firmly depressed. As
the engine starts, there should be a noticeable
“give” in the brake pedal as the vacuum builds
up. Allow the engine to run for at least two

minutes, then switch it off. If the brake pedal
is now depressed it should feel normal, but
further applications should result in the pedal
feeling firmer, with the pedal stroke
decreasing with each application.
2 If the servo does not operate as described,
first inspect the servo unit check valve as
described in Section 16.
3 If the servo unit still fails to operate satisfac-
torily, the fault lies within the unit itself.
Repairs to the unit are not possible - if faulty,
the servo unit must be renewed.

Removal

4 Disconnect the battery negative lead.
5 Remove the windscreen wiper motor/
linkage assembly as described in Chapter 12.
6 Disconnect the wiring from the low brake
fluid level warning sensor.
7 Pull the vacuum check valve from the
grommet in the top of the servo (see
illustration).
8 Unscrew the two nuts securing the master
cylinder to the brake vacuum servo unit, then
ease the master cylinder up to disengage it
from the servo, without disconnecting the
fluid pipes. Take care not to strain the fluid
pipes. If necessary, release the fluid pipes
from their locating clips to enable them to
move sufficiently.
9 Working in the driver’s footwell, remove the
carpet trim panel from under the facia to
expose the pedal assemblies.
10 Where applicable, working under the
facia, unscrew the bolts securing the relay
bracket and the wiring connector bracket(s) to
improve access.

Braking system  9•15

14.4  Pedal pivot bolt and nut (arrowed)

15.7  Pulling the vacuum check valve from

the servo

13.7  Removing the master cylinder from

the vacuum servo

13.5  Master cylinder securing nut

(arrowed)

9

Spread some cloth over the
vacuum servo unit and
surrounding area to catch
fluid drips as the master
cylinder is removed.

11 Where applicable, depress the retaining
clip and detach the end of the clutch cable
from the pedal (see Chapter 5).
12 Disconnect the wiring plug from the stop
light switch.
13 Prise off the brake and clutch pedal
rubbers.
14 Working in the scuttle, unscrew and
remove the four nuts securing the servo to the
scuttle (see illustration).
15 Manoeuvre the complete vacuum servo,
pedal bracket and pedal assembly from the
scuttle (see illustration).
16 Unscrew the four nuts securing the servo
to the pedal bracket, and withdraw the servo
(see illustration). Where applicable recover
the gasket.
17 The servo is a sealed unit, and if faulty,
the complete unit must be renewed.

Refitting

18 Refitting is a reversal of removal, bearing
in mind the following points.

a) Use a new gasket when refitting the

servo.

b) Refit the wiper motor/linkage assembly

with reference to Chapter 12.

c) Check the stop light adjustment with

reference to Section 22.

d) Check the clutch cable adjustment as

described in Chapter 6.

16 Vacuum servo unit check

valve - removal, testing and
refitting

1

Removal

1 For access to the valve, open the bonnet.
The valve is a push-fit in the top of the brake
vacuum servo unit located in the scuttle at the
rear of the engine compartment.
2 Slacken the retaining clip (where fitted), and
disconnect the vacuum hose from the servo
unit check valve.
3 Withdraw the valve from its rubber sealing
grommet, using a pulling and twisting motion.
Remove the grommet from the servo.

Testing

4 Examine the check valve for signs of

damage, and renew if necessary. The valve
may be tested by blowing through it in both
directions. Air should flow through the valve in
one direction only - when blown through from
the servo unit end of the valve. Renew the
valve if this is not the case.
5 Examine the rubber sealing grommet and
flexible vacuum hose for signs of damage or
deterioration, and renew as necessary.

Refitting

6 Fit the sealing grommet into position in the
servo unit.
7 Carefully ease the check valve into position,
taking great care not to displace or damage
the grommet. Reconnect the vacuum hose to
the valve and, where necessary, securely
tighten its retaining clip.

17 Handbrake - checking and

adjustment

2

Checking

1 The handbrake is correctly adjusted when
the rear wheels are fully locked when the
handbrake lever has been pulled up by six to
eight notches. This adjustment tolerance will
be maintained if the automatic adjuster
mechanism is operating correctly to
compensate for brake shoe/pad wear.
2 To check the adjustment, proceed as
follows.
3 Start the engine and release the handbrake.
4 Depress the brake pedal fully two or three
times with the engine running, then stop the
engine.
5 Chock the front wheels, then jack up the
rear of the vehicle, and support securely on
axle stands (see “Jacking and Vehicle
Support”).
6 Apply the handbrake between six to eight
notches, and check that both rear wheels are
locked. If the wheels do not lock, or if the
wheels lock before the handbrake lever has
moved through at least six notches, adjust the
mechanism as follows.

Adjustment - rear drum brakes

7 With the vehicle raised and supported at

the rear, where applicable, remove the rear
body undershield for access to the handbrake
cable adjuster (see illustration).
8 Slacken the locknut on the handbrake
adjuster mechanism and turn the adjuster nut
until the brake shoes are just beginning to
drag on the drums.
9 Pull up the handbrake lever, and check that
both rear wheels are locked with the lever
pulled up between six and eight notches. If
not, readjust using the adjuster nut as
necessary.
10 With the mechanism correctly adjusted,
tighten the adjuster locknut then, where
applicable, refit the rear body undershield,
and lower the vehicle to the ground.
11 Check that the “handbrake on” warning
light illuminates with the handbrake lever at
the first notch of its travel. If necessary, adjust
the switch as described in Chapter 12.

Adjustment - rear disc brakes

12 Where applicable, remove the rear body
undershield for access to the handbrake cable
adjuster, then lower the rear of the vehicle to
the ground.
13 Chock the front wheels, and ensure that
the handbrake is released.
14 Slacken the locknut on the handbrake
adjuster mechanism, then turn the adjuster
nut until there is a clearance of approximately
2.0 mm between the end faces of the cable
end fittings and the handbrake operating
levers on the rear calipers  (see illustration).
15 Operate the levers on the calipers
manually, and check that the levers return
fully to their stops when released.
16 Turn the adjuster nut to give a dimension

9•16 Braking system

15.14  Unscrew the nuts (arrowed)

securing the servo to the scuttle

15.16  Unscrew the nuts (arrowed)

securing the servo to the pedal bracket

17.7  Handbrake cable adjuster (arrowed)

15.15  Removing the vacuum servo/pedal

bracket assembly

of approximately 15.0 mm between the rear
face of the adjuster nut and the end of the
threaded adjuster rod.
17 Proceed as described in paragraphs 9 
to 11.

18 Handbrake lever - removal

and refitting

3

Removal

1 Disconnect the rear of the handbrake
primary cable from the right-hand secondary
cable under the rear of the vehicle, as
described in Section 19.
2 On models with a “lowline” centre console,
pull the handbrake lever up, then unclip the
front edge of the handbrake aperture trim
panel from the top of the centre console.
Withdraw the trim panel over the handbrake
lever.
3 On models with a “highline” centre console,
remove the centre console as described in
Chapter 11.
4 Working under the vehicle, where applicable,
for access to the handbrake lever securing
nuts, remove the exhaust intermediate section
as described in Chapter 4, then remove the
underbody heat shield(s).
5 Unscrew the four handbrake lever securing
nuts, noting that on certain models two of the
nuts also secure an exhaust mounting bracket
(see illustration).
6 Carefully lower the lever assembly from
under the vehicle, and disconnect the wiring
plug from the “handbrake on” warning light
switch. The mounting plate may be stuck to
the floor with sealant, in which case cut
around the plate with a sharp knife. Where
applicable, recover the gasket.
7 Disconnect the end of the cable from the
lever, then release the cable sheath from the
lever mounting plate.

Refitting

8 Refitting is a reversal of removal, bearing in
mind the following points.

a) Use a new gasket or new sealant, as

applicable when refitting the lever

mounting plate to the floor (clean the
mating faces of the mounting plate and
floor).

b) Where applicable, ensure that the exhaust

mounting bracket is in position under the
handbrake lever securing nuts, and refit
the exhaust intermediate section with
reference to Chapter 4.

c) On completion, check and if necessary

adjust the handbrake mechanism as
described in Section 17.

19 Handbrake cables - removal

and refitting

3

Primary cable

Removal

1 Jack up the vehicle and support on axle
stands (see “Jacking and Vehicle Support”).
2 Where applicable, remove the rear body
undershield.
3 To gain access to the cable on certain
models, it may be necessary to remove the
heat shields from under the fuel tank and the
rear underbody. To gain access to remove the
heat shields, it may be necessary to remove
the clamp securing the exhaust rear section to
the intermediate section - this will allow the
exhaust sections to move sufficiently to
manipulate the heat shields out from under
the vehicle.
4 Release the handbrake, then slacken the
locknut on the adjuster mechanism and back
off the adjuster nut (see illustration).
5 Release the primary cable from the clips on
the underbody, then release the cable from
the right-hand secondary cable at the
connector, and from the adjuster bracket.
6 Working under the handbrake lever, detach
the cable sheath from the lever mounting
plate.
7 On models with a “lowline” centre console,
pull the handbrake lever up, then unclip the
front edge of the handbrake aperture trim
panel from the top of the centre console.
Withdraw the trim panel over the handbrake
lever.

8 On models with a “highline” centre console,
remove the centre console as described in
Chapter 11.
9 Pull the handbrake lever up to the 5th notch
of travel, for access to the end of the cable.
10 Pull the end of the cable forwards and
down to release it from the lug on the lever.
11 Feed the cable down through the lever
mounting plate, and withdraw it from under
the vehicle.

Refitting

12 Refitting is a reversal of removal, bearing
in mind the following points.

a) Ensure that the cable is routed correctly,

and is free from kinks.

b) On completion, check and if necessary

adjust the handbrake mechanism as
described in Section 17.

Secondary cable - 
models with rear drum brakes

Removal

13 Proceed as described in paragraphs 1
and 2.
14 Slacken the locknut on the adjuster
mechanism and back off the adjuster nut.
15 If the left-hand cable is being removed,
remove the adjuster nut from the end of the
threaded adjuster rod, then detach the end of
the cable from the adjuster bracket.
16 If the right-hand cable is being removed,
disconnect the secondary cable from the
primary cable at the connector.
17 Remove the relevant brake drum as
described in Section 9.
18 Using a pair of pliers, unhook the end of
the handbrake cable from the operating lever
on the trailing brake shoe.
19 Where applicable, tap the cable sheath
end fitting from the aperture in the brake
backplate, and feed the cable through the

Braking system  9•17

19.4  Handbrake lever and cable

components

1  Handbrake lever
2  Switch assembly

3  Primary cable
4  Secondary cables

18.5  Three of the handbrake lever

securing nuts (arrowed)

9

17.14  Adjust the clearance between the

cable end fitting (A) and the handbrake

operating lever (B) at the caliper

backplate (it may be necessary to remove the
brake shoes for access - see Section 6) (see
illustration).
20 Release the cable from the underbody
clips, noting its routing, and withdraw the
cable from under the vehicle.

Refitting

21 Refitting is a reversal of removal, bearing
in mind the following points.

a) Ensure that the cable is routed correctly,

and is free from kinks.

b) Refit the brake drum (see Section 9).
c) On completion, check and if necessary

adjust the handbrake mechanism as
described in Section 17.

Secondary cable - 
models with rear disc brakes

Removal

22 Proceed as described in paragraphs 1
and 2.
23 Slacken the locknut on the adjuster
mechanism and back off the adjuster nut.
24 If the left-hand cable is being removed,
remove the adjuster nut from the end of the
threaded adjuster rod, then detach the end of
the cable from the adjuster bracket.
25 If the right-hand cable is being removed,
disconnect the secondary cable from the
primary cable at the connector.
26 Disconnect the end of the cable from the
operating lever on the caliper, then release the
cable sheath from the caliper bracket.
27 Release the cable from the underbody
clips, noting its routing, and withdraw the
cable from under the vehicle.

Refitting

28 Refitting is a reversal of removal, bearing
in mind the following points.

a) Ensure that the cable is routed correctly,

and is free from kinks.

b) On completion, check and if necessary

adjust the handbrake mechanism as
described in Section 17.

20 Handbrake “on” warning

light switch - removal and
refitting

3

Removal

1 Remove the handbrake lever as described
in Section 18.
2 Mark the position of the switch bracket on
the handbrake lever assembly.
3 Unbolt the switch bracket from the
handbrake lever assembly, and unclip the
switch.

Refitting

4 Refitting is a reversal of removal. If
necessary, the position of the switch bracket
can be adjusted (the hole in the bracket is
elongated) to ensure that the warning light is
off with the handbrake released, and on with
the handbrake applied.

21 Rear brake pressure-

regulating valve (underbody-
mounted) - removal and refitting

5

Note: On some models equipped with rear
drum brakes, the pressure regulating valves
are integral with the rear wheel cylinders. If
fitted, the underbody-mounted pressure
regulating valve is located on the right-hand
side of the rear axle assembly.

Note: On refitting, the valve must be adjusted
using specialist test equipment. This task must
be entrusted to Peugeot dealer.

Removal

1 Chock the front wheels, then jack up the
rear of the vehicle and support securely on
axle stands (see “Jacking and Vehicle
Support”).
2 Unhook the valve operating spring from the
bracket attached to the trailing arm.

3 Place a suitable container under the valve,
then disconnect the fluid pipes from the valve.
Plug the open ends of the pipes and the valve
to prevent dirt ingress and to reduce fluid
spillage.
4 Unscrew the securing bolts, and withdraw
the valve from its mounting bracket (see
illustration).

Refitting

5 Refitting is a reversal of removal, but on
completion bleed the hydraulic system as
described in Section 2, and have the valve
adjusted by a Peugeot dealer.

22 Stop-light switch - removal,

refitting and adjustment

2

Removal

1 The switch is mounted on the brake pedal
bracket (see illustration).
2 Disconnect the battery negative lead.
3 If necessary to improve access, remove the
carpet trim panel from under the driver’s side
facia.
4 Disconnect the wiring plug from the switch,
then pull the switch from the bracket to
remove it.

Refitting

5 Depress the brake pedal fully.
6 Push the switch fully into its bracket as far
as the stop.
7 Release the brake pedal, and allow it to
contact the switch. The switch should retract,
and automatically reset itself.
8 Reconnect the wiring plug, then reconnect
the battery negative lead.
9 Check that the stop lights operate when the
brake pedal is depressed with the ignition
switched on.
10 If the stop lights fail to operate, and the
wiring is in good order, renew the switch.

Adjustment

11 The switch is self-adjusting, and can be
reset by removing and then refitting it as
described previously in this Section.
12 If the switch fails to operate satisfactorily
after removal and refitting, renew the switch.

9•18 Braking system

22.1  Stop-light switch (arrowed) 

on brake pedal bracket

21.4 Rear brake pressure-regulating valve

securing bolts (arrowed)

19.19  Tapping the handbrake cable sheath

end fitting from the brake backplate

Warning: Do not attempt to
remove the pressure-regulating
valve on models equipped with
the Bendix “integral” ABS

system. On these models, the task should
be entrusted to a Peugeot dealer - see
Section 23.