Peugeot 405. Manual - part 48

shock absorber upper and lower securing
nuts. Recover the washers (see illustration).
4 Tap the bolts from the mountings to free the
shock absorber, then withdraw the unit from
under the vehicle.

Testing

5 Examine the shock absorber for signs of
fluid leakage or damage. Test the operation of
the shock absorber, while holding it in an
upright position, by moving the piston through
a full stroke and then through short strokes of
50 to 100 mm. In both cases, the resistance
felt should be smooth and continuous. If the
resistance is jerky, or uneven, or if there is any
visible sign of wear or damage, renewal is
necessary.
6 Also check the rubber mounting bushes for
damage and deterioration. New bushes can
be fitted using a long bolt, nut and spacers to
draw the bush into position. Lubricate the new
bush with soapy water to aid fitting.
7 Inspect the shanks of the mounting bolts
for signs of wear or damage, and renew as
necessary.

Refitting

8 Prior to refitting the shock absorber, mount
it upright in the vice, and operate it fully
through several strokes in order to prime it.
Apply a smear of multi-purpose grease to
both the shock absorber mounting bolts.
9 Manoeuvre the shock absorber into
position, and insert its mounting bolts (with
washers in place). Note that the bolts fit from
the inside of the vehicle, ie the nuts fit on the
roadwheel side of the shock absorber.
10 Fit the washers and new nuts to the
mounting bolts, but do not tighten the fixings
at this stage.
11 Measure the distance between the shock
absorber bolt centres, and load the vehicle (by
adding weight to the luggage compartment)
until a distance of 328.0 mm is obtained
between the bolt centres. Tighten the shock
absorber mounting nuts and bolts to the
specified torque.
12 Drive the vehicle off the ramps.

14 Rear axle assembly - 

removal and refitting

4

Removal

Note: Before carrying out this procedure, it is
advisable to run the fuel tank as near empty as
possible to minimise the amount of fuel which
has to be drained from the tank.
1 Chock the front wheels, then jack up the
rear of the vehicle and support securely on
axle stands, until the trailing arms are at
maximum extension, with the roadwheels still
resting on the ground (see “Jacking and
Vehicle Support”).
2 Where applicable, remove the rear
underbody shield.
3 Remove the rear and intermediate exhaust
sections as described in Chapter 4.
4 Empty the fuel tank by either disconnecting
the filler pipe and draining, or by siphoning the
fuel out through the filler neck. In either case,
collect the fuel in a container which can be
sealed.
5 Disconnect the fuel filler pipe from the tank
(If not already done). Plug the open ends of
the tank and the hose to prevent dirt ingress.
6 Remove the rear exhaust heat shield from
the underbody.
7 Disconnect the handbrake cables from the
adjuster mechanism under the rear
underbody, with reference to Chapter 9.
8 Release the handbrake cables from any
clips and brackets, and move them clear of
the suspension components to facilitate
removal.
9 Loosen the fuel tank support strap bolts as
far as possible without removing them, and
lower the fuel tank.
10 Disconnect the brake fluid pipes at the
unions on the rear suspension assembly, with
reference to Chapter 9. Plug the open ends of
the unions.
11 On models with a load-sensitive rear
brake pressure regulating valve, disconnect
the hydraulic pipes at the valve. Again, plug
the opens ends of the pipes and the valve.
12 Where applicable, remove the rear ABS
wheel sensors. Note that there is no need to

disconnect the wiring connectors, but unclip
the wiring harnesses from the rear suspension
components, and move the sensors to one
side, clear of the working area.
13 Place a trolley jack under the rear
suspension tubular crossmember to support
the suspension assembly.
14 Make a final check to ensure that all
relevant pipes and wires have been
disconnected to facilitate removal of the
suspension assembly.
15 Using a long-reach splined adapter,
unscrew the suspension assembly rear
securing bolts, accessible through the holes
in the suspension assembly side members
(see illustration).
16 Working at the front of the suspension
assembly, unscrew the two bolts on each side
securing the front mountings to the
underbody 

(see illustration).

17 Lower the trolley jack slightly, and pull the
suspension rearwards. If necessary, raise the
vehicle body in order for the suspension to
clear the fuel tank, then withdraw the
suspension assembly from under the vehicle.

Refitting

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

a) Tighten all fixings to the specified torque.
b) Bleed the brake hydraulic system as

described in Chapter 9.

c) Adjust the handbrake mechanism as

described in Chapter 9.

d) On completion, have the rear ride height

checked by a Peugeot dealer.

15 Vehicle ride height - checking

5

Checking of the vehicle ride height requires

the use of Peugeot special tools to accurately
compress the suspension in a suspension
checking bay.

The operation should be entrusted to a

Peugeot dealer, as it not possible to carry out
checking accurately without the use of the
appropriate tools.

Suspension and steering  10•11

14.16  Unscrew the two bolts (arrowed) on

each side securing the suspension

mountings to the body

14.15  Using a long-reach splined adapter

to unscrew a suspension assembly 

rear securing bolt

13.3  Rear shock absorber 

upper mounting bolt (arrowed)

10

16 Steering wheel - 

removal and refitting

2

Models without air bag

Removal

Note: A new securing nut and washer must be
used on refitting.
1 Position the front wheel in the straight-
ahead position.
2 Prise out the centre trim from the steering
wheel.
3 Make alignment marks between the end of
the steering column shaft and the steering
wheel boss.
4 Using a long-reach socket and extension
bar, unscrew the steering wheel securing nut
by a few turns (see illustration).
5 Using the palms of the hands, strike the
underside of the steering wheel firmly to
release the wheel from the column splines.
6 Remove the securing nut, and lift off the
steering wheel.

Refitting

7 Refitting is a reversal of removal, but align
the marks made before removal, fit a new
washer, and tighten the new securing nut to
the specified torque.

Models with air bag

a) Do not drop the steering wheel, or subject

it to impacts.

b) Do not attempt to dismantle the steering

wheel.

c) Do not attempt to fit a steering wheel

from another model of vehicle (even a
different model of Peugeot 405), as the air
bag control module is calibrated for each
particular model.

Removal

Note: A new securing nut and washer must be
used on refitting.
8 Remove the air bag unit (see Chapter 12).

9 Set the front wheels in the straight-ahead
position, and engage the steering lock.
10 Make alignment marks between the end
of the steering column shaft and the steering
wheel boss.
11 Unscrew the steering wheel retaining nut
by several threads.
12 Using the palms of the hands, strike the
underside of the steering wheel firmly to
release the wheel from the column splines.
13 Separate the two halves of the air bag
control unit wiring connector.
14 Remove the steering wheel retaining nut,
and recover the washer.
15 Carefully withdraw the steering wheel,
feeding the wiring harness (connecting the
rotary connector to the air bag control unit)
through the wheel as it is withdrawn. Do not
disturb the air bag control unit wiring
connector (located in the steering wheel).

Refitting

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

a) Align the marks made before removal.
b) Fit a new washer, and tighten the new nut

to the specified torque.

c) Refit the air bag unit (see Chapter 12).

17 Steering column - removal,

inspection and refitting

3

Removal

1 Disconnect the battery negative lead.

2 Where applicable, remove the air bag as
described in Chapter 12.
3 Remove the steering wheel (see Section 16).
4 Remove the steering column shrouds with
reference to Chapter 11.
5 Remove the steering column stalk switches
as described in Chapter 12.
6 On models up the 1992, release the
securing clips, and lower the fusebox panel
from the facia.
7 Working in the footwell, unclip the carpet
trim panel from under the facia for access to
the steering column pinch-bolt.
8 Working under the steering column,
disconnect the three ignition switch wiring
connectors (see illustration). Similarly, where
applicable disconnect the air bag wiring
harness connector.
9 Working in the driver’s footwell, make
alignment marks on the intermediate shaft
and the steering column shaft to aid refitting.
10 Unscrew the clamp bolt securing the
steering column shaft to the intermediate
shaft (see illustration).
11 Unscrew the two lower steering column
securing nuts (models up to 1992) or bolts
(models from 1993) (see illustration).
12 Unscrew the upper steering column
securing nuts, then withdraw the steering
column from the vehicle (see illustration).
13 To remove the intermediate shaft, with the
steering column removed, proceed as follows.

a) Working in the engine compartment,

unscrew the shaft-to-steering gear pinion
pinch-bolt.

b) Withdraw the shaft through the bulkhead

grommet into the vehicle interior.

10•12 Suspension and steering

16.4  Unscrewing the steering wheel nut

17.10  Unscrewing the steering column

shaft-to intermediate shaft clamp bolt

17.12  Steering column upper securing

nuts (arrowed) - models up to 1992

17.11  Lower steering column securing

nuts (arrowed) - models from 1993

17.8  Ignition switch wiring connectors

(arrowed) - models from 1993

Warning: Refer to the
precautions given in Chapter 12,
Section 24 before proceeding.
Note that the air bag control

module is integral with the steering wheel.
Additionally, note the following points.

Inspection

14 The steering column incorporates a
telescopic safety feature. In the event of a
front-end crash, the shaft collapses and
prevents the steering wheel injuring the driver.
Before refitting the steering column, examine
the column and mountings for signs of
damage and deformation, and renew as
necessary.
15 Check the steering column shaft for signs
of free play in the column bushes, and check
the universal joint for signs of damage or
roughness in the joint bearings. If any damage
or wear is found on the steering column
universal joint or shaft bushes, the column
must be renewed as an assembly.
16 Similarly, where applicable, examine the
intermediate shaft and renew if the universal
joint is worn.
17 If Nyloc-type nuts were used to secure the
steering column, these must be renewed as a
matter of course.

Refitting

18 Refitting is a reversal of removal, bearing
in mind the following points.
19 If the intermediate shaft has been
removed, make sure that the bulkhead
grommet is not dislodged on refitting.
20 Align the marks made on the intermediate
shaft and the steering column shaft before
removal.
21 On models fitted with an air bag, do not
tighten the column shaft pinch-bolt or refit the
trim panel until the procedure given in
paragraph 27 has been carried out.
22 Ensure that the column height adjuster
lever is in the released position when the
column securing nuts/bolts are refitted.
23 Renew any Nyloc nuts.
24 Tighten all fixings to the specified torque.
25 Refit the steering wheel as described in
Section 16.
26 Where applicable, refit the air bag as
described in Chapter 12.
27 On models with an air bag, on completion,
carry out the following procedure.

a) Move the steering column to its fully

raised position, then check that the
clearance between the rear face of the
steering wheel and the front faces of the

steering column shrouds is 8.0 mm. If the
clearance is not as specified, proceed as
follows.

b) Loosen the steering column shaft-to-

intermediate shaft pinch-bolt, then slide
the steering shaft as necessary to give the
specified clearance between the steering
wheel and the shrouds.

c) Tighten the pinch-bolt, and refit the trim

panel.

18 Ignition switch/steering

column lock - removal and
refitting

3

Removal

1 Disconnect the battery negative lead.
2 Remove the steering column shrouds as
described in Chapter 11.
3 Working under the steering column, locate
the three ignition switch wiring connectors,
and separate the two halves of each
connector. Unclip the connectors from the
bracket, and release the wiring harness from
any clips.
4 Insert the ignition key and turn it to align
with the small arrow on the lock rim.
5 Unscrew the lock securing screw (see
illustration).
6 Using a small screwdriver, depress the lock
retaining lug, whilst simultaneously pulling the
lock from the housing using the key (see
illustration).
7 Withdraw the lock assembly, feeding the
wiring up through the steering column tube.

8 To separate the ignition switch from the
lock, proceed as follows.

a) Remove the two securing screws from the

rear of the lock (see illustration).

b) Slide the rear section from the lock body

(see illustration).

c) Slide the ignition switch unit from the lock

body (see illustration).

Refitting

9 When refitting the ignition switch to the
lock, first ensure that the ignition key is
removed from the lock, and ensure that the
switch wiper is turned anti-clockwise as far as
possible. Check that the lugs on the wiper
engage with the cut-outs in the lock body.
10 Refit the lock using a reversal of the
removal procedure.

19 Steering gear assembly -

removal, overhaul and refitting

3

Removal

Note: All Nyloc nuts disturbed on removal
must be renewed as a matter of course. These
nuts have threads which are pre-coated with
locking compound (this is only effective once).
1 Disconnect the battery negative lead.
2 Apply the handbrake, then jack up the front
of the vehicle and support securely on axle
stands (see “Jacking and Vehicle Support”).
Remove the roadwheels.
3 If desired, to improve access, remove the
wheel arch liners, referring to Chapter 11.

Suspension and steering  10•13

18.8a  Remove the two lock 

securing screws . . .

18.8c  . . . and slide out the ignition switch

18.8b  . . . slide the rear section from the

lock body . . .

18.6  Depress the lock retaining lug, whilst

pulling out the lock using the key

18.5  Unscrewing the lock securing screw

10

4 On models with power steering, drain the
hydraulic fluid as follows.

a) Remove the cap from the fluid reservoir.
b) Place a container under the high pressure

fluid pipe union on the steering gear, then
unscrew the union.

c) Allow the fluid to drain into the container.
d) Turn the steering from lock-to-lock

several times to completely drain the
system.

e) Disconnect the low pressure hose from

the steering gear.

5 Where applicable, unbolt the heat shield
from the steering gear.
6 On manual gearbox models, prise the cap
from the gear linkage pivot, then unscrew the
linkage pivot bolt. Move the gear linkage clear
of the steering gear, and tie it up out of the
way using wire or string.
7 Make alignment marks between the end of
the intermediate shaft and the steering gear
pinion, then unscrew the clamp bolt securing
the intermediate shaft universal joint to the
pinion.
8 Working on one side of the vehicle, slacken
and partially unscrew the track rod end nut
(unscrew the nut as far as the end of the
threads on the balljoint to prevent damage to
the threads as the joint is released), then
release the balljoint using a balljoint separator
tool (see illustration). Remove the nut.
9 Repeat the procedure on the remaining side
of the vehicle.
10 Unscrew the two bolts securing the
steering gear to the subframe. Recover the
washers, and spacers, taking careful note of
their positions to ensure correct refitting.
11 Rotate the steering gear around its
horizontal axis, so that the pinion is at the
bottom, then withdraw the assembly from
under the right-hand wheel arch.

Overhaul

12 Examine the steering gear assembly for
signs of wear or damage, and check that the
rack moves freely throughout the full length of
its travel, with no signs of roughness or
excessive free play between the steering gear
pinion and rack. It is possible to overhaul the
steering gear assembly housing components,
but this task should be entrusted to a Peugeot
dealer. The only components which can be
renewed easily by the home mechanic are the

steering gear gaiters, the track rod balljoints
and the track rods. Track rod, track rod
balljoint and steering gear gaiter renewal
procedures are covered in Sections 24, 23
and 20 respectively.
13 On models with power steering, inspect
all the steering gear fluid unions for signs of
leakage, and check that all union nuts are
securely tightened. Also examine the steering
gear hydraulic ram for signs of fluid leakage or
damage, and if necessary renew it.

Refitting

Note:

There have been a number of

modifications to the steering gear and the
subframe, which alter the dimension of the
steering gear-to-subframe mounting points.
Different thicknesses of spacer are fitted
between the rack and the subframe, and
under the mounting bolt heads. Due to the
many combinations of different components,
and the non-interchangeability of the different
components, if either the steering gear or
subframe are to be renewed, the advice of a
Peugeot dealer should be sought.
14 Refitting is a reversal of removal, bearing
in mind the following points.

a) Use new nuts when reconnecting the

track rod ends.

b) Tighten all fixings to the specified torque.
c) On models with power steering, fill and

bleed the hydraulic system as described
in Section 21.

d) On completion, have the front wheel

alignment checked at the earliest
opportunity.

20 Steering gear 

rubber gaiters - renewal

4

Manual steering gear

1 Remove the track rod balljoint as described
in Section 23.
2 Mark the correct fitted position of the gaiter
on the track rod, then release the retaining
clips and slide the gaiter off the steering gear
housing and track rod end.
3 Thoroughly clean the track rod and the
steering gear housing, using fine abrasive
paper to polish off any corrosion, burrs or
sharp edges, which might damage the new
gaiter’s sealing lips on installation. Scrape off
all the grease from the old gaiter, and apply it
to the track rod inner balljoint. (This assumes
that grease has not been lost or contaminated
as a result of damage to the old gaiter. Use
fresh grease if in doubt.)
4 Carefully slide the new gaiter onto the track
rod end, and locate it on the steering gear
housing. Align the outer edge of the gaiter
with the mark made on the track rod prior to
removal, then secure it in position with new
retaining clips.
5 Refit the track rod balljoint as described in
Section 23.

Power-assisted steering gear

6 On power-assisted steering gear assem-
blies, it is only possible to renew the gaiter
nearest the drive pinion, ie the right-hand
gaiter on right-hand-drive models, and the
left-hand gaiter on left-hand-drive models.
This can be renewed as described above in
paragraphs 1 to 5.
7 The task of renewing the opposite gaiter
should be entrusted to a Peugeot dealer. This
is necessary since it is not possible to pass
the gaiter over the steering rack stud to which
the hydraulic ram is fixed. Therefore, the
steering gear must be dismantled and the
rack removed from the housing to allow the
gaiter to be renewed.
8 The only task on this end of the assembly
which can be carried out by the home
mechanic is the renewal of the track rod inner
balljoint dust cover. The dust cover can be
renewed once the track rod balljoint has been
removed as described in Section 23. On
refitting, ensure that the dust cover is
correctly located on the track rod and steering
rack, then refit the balljoint.

21 Power steering system -

bleeding

2

1 This procedure will only be necessary when
any part of the hydraulic system has been
disconnected.
2 Referring to Chapter 1, remove the fluid
reservoir filler cap, and top-up with the
specified fluid to the maximum level mark.
3 With the engine stopped, slowly move the
steering from lock-to-lock several times to
purge out the trapped air, then top-up the
level in the fluid reservoir. Repeat this
procedure until the fluid level in the reservoir
does not drop any further.
4 Start the engine, then slowly move the
steering from lock-to-lock several times to
purge out any remaining air in the system.
Repeat this procedure until bubbles cease to
appear in the fluid reservoir.
5 If, when turning the steering, an abnormal
noise is heard from the fluid lines, it indicates
that there is still air in the system. Check this
by turning the wheels to the straight-ahead
position and switching off the engine. If the
fluid level in the reservoir rises, then air is
present in the system, and further bleeding is
necessary.
6 Once all traces of air have been removed
from the power steering hydraulic system,
turn the engine off and allow the system to
cool. Once cool, check that fluid level is up to
the maximum mark on the power steering
fluid reservoir, topping-up if necessary (refer
to “Weekly Checks” if necessary).

10•14 Suspension and steering

19.8  Using a balljoint separator tool to

disconnect the track rod end balljoint