Peugeot 405. Manual - part 73

2 Cooling system

Fault Finding

REF•15

REF

Overheating

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Insufficient coolant in system (“Weekly checks”).

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Thermostat faulty (Chapter 3).

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Radiator core blocked, or grille restricted (Chapter 3).

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Electric cooling fan or thermostatic switch faulty (Chapter 3).

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Pressure cap faulty (Chapter 3).

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Ignition timing incorrect, or ignition system fault 
(Chapters 1 and 5B).

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Inaccurate temperature gauge sender unit (Chapter 3).

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Airlock in cooling system (Chapter 1).

Overcooling

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Thermostat faulty (Chapter 3).

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Inaccurate temperature gauge sender unit (Chapter 3).

External coolant leakage

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Deteriorated or damaged hoses or hose clips (Chapter 1).

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Radiator core or heater matrix leaking (Chapter 3).

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Pressure cap faulty (Chapter 3).

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Water pump internal seal leaking (Chapter 3).

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Water pump gasket leaking (Chapter 3).

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Boiling due to overheating (Chapter 3).

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Core plug leaking (Chapter 2C).

Internal coolant leakage

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Leaking cylinder head gasket (Chapter 2A or 2B).

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Cracked cylinder head or cylinder block (Chapter 2A, 2B or 2C).

Corrosion

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Infrequent draining and flushing (Chapter 1).

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Incorrect coolant mixture or inappropriate coolant type (Chapter 1).

3 Fuel and exhaust systems

Excessive fuel consumption

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Air filter element dirty or clogged (Chapter 1).

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Faulty carburettor (Chapter 4A).

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Fuel injection system fault (Chapter 4B or 4C).

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Ignition timing incorrect or ignition system fault 
(Chapters 1 and 5B).

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Tyres under-inflated (“Weekly checks”).

Fuel leakage and/or fuel odour

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Damaged fuel tank, pipes or connections 
(Chapters 1 and 4A, 4B or 4C).

Excessive noise or fumes from exhaust system

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Leaking exhaust system or manifold joints (Chapters 1 and 4D).

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Leaking, corroded or damaged silencers or pipe 
(Chapters 1 and 4D).

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Broken mountings causing body or suspension contact 
(Chapter 4D).

4 Clutch

Pedal travels to floor - 
no pressure or very little resistance

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Broken clutch cable (Chapter 6).

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Incorrect clutch cable adjustment  (Chapter 6).

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Broken clutch release bearing or arm (Chapter 6).

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Broken diaphragm spring in clutch pressure plate (Chapter 6).

Clutch fails to disengage (unable to select gears)

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Incorrect clutch cable adjustment (Chapter 6).

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Clutch disc sticking on splines (Chapter 6).

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Clutch disc sticking to flywheel or pressure plate (Chapter 6).

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Faulty pressure plate assembly (Chapter 6).

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Clutch release mechanism worn or incorrectly assembled
(Chapter 6).

Clutch slips (engine speed increases, 
with no increase in vehicle speed)

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Incorrect clutch cable adjustment (Chapter 6).

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Clutch disc linings excessively worn (Chapter 6).

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Clutch disc linings contaminated with oil or grease (Chapter 6).

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Faulty pressure plate or weak diaphragm spring (Chapter 6).

Judder as clutch is engaged

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Clutch disc linings contaminated with oil or grease (Chapter 6).

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Clutch disc linings excessively worn (Chapter 6).

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Clutch cable sticking or frayed (Chapter 6).

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Faulty or distorted pressure plate or diaphragm spring (Chapter 6).

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Worn or loose engine or gearbox mountings (Chapter 2A or 2B).

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Clutch disc hub or shaft splines worn (Chapter 6).

Noise when depressing or releasing clutch pedal

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Worn clutch release bearing (Chapter 6).

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Worn or dry clutch pedal bushes (Chapter 6).

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Faulty pressure plate assembly (Chapter 6).

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Pressure plate diaphragm spring broken (Chapter 6).

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Broken clutch disc cushioning springs (Chapter 6).

7 Driveshafts

5 Manual transmission

REF•16

Fault Finding

Noisy in neutral with engine running

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Primary gears and bearings worn (noise apparent with clutch
pedal released, but not when depressed) (Chapter 7A).*

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Clutch release bearing worn (noise apparent with clutch pedal
depressed, possibly less when released) (Chapter 6).

Noisy in one particular gear

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Worn, damaged or chipped gear teeth (Chapter 7A).*

Difficulty engaging gears

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Clutch fault (Chapter 6).

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Worn or damaged gear linkage (Chapter 7A).

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Incorrectly-adjusted gear linkage (Chapter 7A).

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Worn synchroniser units (Chapter 7A).*

Jumps out of gear

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Worn or damaged gear linkage (Chapter 7A).

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Incorrectly-adjusted gear linkage (Chapter 7A).

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Worn synchroniser units (Chapter 7A).*

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Worn selector forks (Chapter 7A).*

Vibration

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Lack of oil (Chapter 1).

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Worn bearings (Chapter 7A).*

Lubricant leaks

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Leaking differential output oil seal (Chapter 7A).

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Leaking housing joint (Chapter 7A).*

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Leaking input shaft oil seal (Chapter 7A).*

*Although the corrective action necessary to remedy the symptoms
described is beyond the scope of the home mechanic, the above
information should be helpful in isolating the cause of the condition,
so that the owner can communicate clearly with a professional
mechanic.

6 Automatic transmission

Note: Due to the complexity of the automatic transmission, it is
difficult for the home mechanic to properly diagnose and service this
unit. For problems other than the following, the vehicle should be
taken to a dealer service department or automatic transmission
specialist.

Fluid leakage

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Automatic transmission fluid is usually deep red in colour. Fluid
leaks should not be confused with engine oil, which can easily
be blown onto the transmission by air flow.

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To determine the source of a leak, first remove all built-up dirt
and grime from the transmission housing and surrounding areas,
using a degreasing agent or by steam-cleaning. Drive the vehicle
at low speed, so that air flow will not blow the leak far from its
source. Raise and support the vehicle, and determine where the
leak is coming from. The following are common areas of leakage.

a) Fluid pan (Chapter 1 and 7B).
b) Dipstick tube (Chapter 1 and 7B).
c) Transmission-to-fluid cooler fluid pipes/unions (Chapter 7B).

Transmission fluid brown, or has burned smell

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Transmission fluid level low, or fluid in need of renewal 
(Chapter 1).

General gear selection problems

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Chapter 7B deals with checking and adjusting the selector cable
on automatic transmissions. The following are common
problems which may be caused by a poorly-adjusted cable:

a) Engine starting in gears other than Park or Neutral.
b) Indicator on gear selector lever pointing to a gear other than the

one actually being used.

c) Vehicle moves when in Park or Neutral.
d) Poor gear shift quality, or erratic gear changes.

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Refer to Chapter 7B for the selector cable adjustment procedure.

Transmission will not downshift (kickdown) 
with accelerator pedal fully depressed

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Low transmission fluid level (Chapter 1).

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Incorrect selector cable adjustment (Chapter 7B).

Engine will not start in any gear, 
or starts in gears other than Park or Neutral

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Incorrect starter/inhibitor switch adjustment - where applicable
(Chapter 7B).

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Incorrect selector cable adjustment (Chapter 7B).

Transmission slips, shifts roughly, is noisy, 
or has no drive in forward or reverse gears

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There are many probable causes for the above problems, but the
home mechanic should be concerned with only one possibility -
fluid level. Before taking the vehicle to a dealer or transmission
specialist, check the fluid level and condition of the fluid as
described in Chapter 1. Correct the fluid level as necessary, or
change the fluid and filter if needed. If the problem persists,
professional help will be necessary.

Clicking or knocking noise on turns 
(at slow speed on full-lock)

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Lack of constant velocity joint lubricant, possibly due to
damaged gaiter (Chapter 8).

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Worn outer constant velocity joint (Chapter 8).

Vibration when accelerating or decelerating

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Worn inner constant velocity joint (Chapter 8).

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Bent or distorted driveshaft (Chapter 8).

Fault Finding

REF•17

REF

8 Braking system

Note: Before assuming that a brake problem exists, make sure that
the tyres are in good condition and correctly inflated, that the front
wheel alignment is correct, and that the vehicle is not loaded with
weight in an unequal manner.

Vehicle pulls to one side under braking

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Worn, defective, damaged or contaminated front or rear brake
pads/shoes on one side (Chapters 1 and 9).

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Seized or partially-seized brake caliper/wheel cylinder piston
(Chapter 9).

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A mixture of brake pad/shoe lining materials fitted between sides
(Chapter 9).

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Brake caliper mounting bolts loose (Chapter 9).

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Worn or damaged steering or suspension components 
(Chapters 1 and 10).

Noise (grinding or high-pitched squeal) 
when brakes applied

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Brake pad/shoe friction lining material worn down to metal
backing (Chapters 1 and 9).

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Excessive corrosion of brake disc/drum - may be apparent after
the vehicle has been standing for some time (Chapters 1 and 9).

Excessive brake pedal travel

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Faulty master cylinder (Chapter 9).

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Air in hydraulic system (Chapter 9).

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Faulty vacuum servo unit (Chapter 9).

Brake pedal feels spongy when depressed

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Air in hydraulic system (Chapter 9).

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Deteriorated flexible rubber brake hoses (Chapters 1 and 9).

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Master cylinder mountings loose (Chapter 9).

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Faulty master cylinder (Chapter 9).

Excessive brake pedal effort 
required to stop vehicle

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Faulty vacuum servo unit (Chapter 9).

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Disconnected, damaged or insecure brake servo vacuum hose
(Chapters 1 and 9).

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Primary or secondary hydraulic circuit failure (Chapter 9).

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Seized brake caliper/wheel cylinder piston(s) (Chapter 9).

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Brake pads/shoes incorrectly fitted (Chapter 9).

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Incorrect grade of brake pads/shoes fitted (Chapter 9).

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Brake pads/shoes contaminated (Chapter 9).

Judder felt through brake pedal or 
steering wheel when braking

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Excessive run-out or distortion of brake disc/drum (Chapter 9).

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Brake pad/shoe linings worn (Chapters 1 and 9).

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Brake caliper mounting bolts loose (Chapter 9).

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Wear in suspension or steering components or mountings
(Chapters 1 and 10).

Brakes binding

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Seized brake caliper/wheel cylinder piston(s) (Chapter 9).

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Incorrectly-adjusted handbrake mechanism (Chapter 9).

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Faulty master cylinder (Chapter 9).

Rear wheels locking under normal braking

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Seized brake caliper/wheel cylinder piston(s) (Chapter 9).

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Faulty brake pressure regulator (Chapter 9).

9 Suspension and steering

Note: Before diagnosing suspension or steering faults, be sure that
the trouble is not due to incorrect tyre pressures, mixtures of tyre
types, or binding brakes.

Vehicle pulls to one side

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Defective tyre (Chapter 1).

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Excessive wear in suspension or steering components 
(Chapters 1 and 10).

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Incorrect front wheel alignment (Chapter 10).

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Accident damage to steering or suspension components
(Chapters 1 and 10).

Wheel wobble and vibration

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Front roadwheels out of balance (vibration felt mainly through
the steering wheel) (Chapter 10).

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Rear roadwheels out of balance (vibration felt throughout the
vehicle) (Chapter 10).

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Roadwheels damaged or distorted (Chapter 10).

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Faulty or damaged tyre (Chapter 1).

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Worn steering or suspension joints, bushes or components
(Chapters 1 and 10).

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Wheel nuts loose (Chapter 10).

Excessive pitching and/or rolling around
corners, or during braking

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Defective shock absorbers (Chapters 1 and 10).

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Broken or weak coil spring and/or suspension component
(Chapters 1 and 10).

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Worn or damaged anti-roll bar or mountings (Chapter 10).

Wandering or general instability

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Incorrect front wheel alignment (Chapter 10).

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Worn steering or suspension joints, bushes or components
(Chapters 1 and 10).

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Roadwheels out of balance (Chapter 10).

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Faulty or damaged tyre (“Weekly checks”).

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Wheel nuts loose (Chapter 10).

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Defective shock absorbers (Chapters 1 and 10).

Excessively-stiff steering

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Lack of steering gear lubricant (Chapter 10).

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Seized track rod end or suspension balljoint (Chapters 1 and 10).

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Broken or incorrectly adjusted auxiliary drivebelt (Chapter 1).

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Incorrect front wheel alignment (Chapter 10).

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Steering rack or column bent or damaged (Chapter 10).

Excessive play in steering

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Worn steering column universal joint(s) (Chapter 10).

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Worn steering track rod end balljoints (Chapters 1 and 10).

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Worn rack-and-pinion steering gear (Chapter 10).

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Worn steering or suspension joints, bushes or components
(Chapters 1 and 10).

Lack of power assistance

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Broken or incorrectly-adjusted auxiliary drivebelt (Chapter 1).

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Incorrect power steering fluid level (“Weekly checks”).

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Restriction in power steering fluid hoses (Chapter 1).

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Faulty power steering pump (Chapter 10).

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Faulty rack-and-pinion steering gear (Chapter 10).

9 Suspension and steering (continued)

REF•18

Fault Finding

Tyre wear excessive

Tyres worn on inside or outside edges

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Tyres under-inflated (wear on both edges) (“Weekly checks”).

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Incorrect camber or castor angles (wear on one edge only)
(Chapter 10).

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Worn steering or suspension joints, bushes or components
(Chapters 1 and 10).

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Excessively-hard cornering.

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Accident damage.

Tyre treads exhibit feathered edges

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Incorrect toe setting (Chapter 10).

Tyres worn in centre of tread

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Tyres over-inflated (“Weekly checks”).

Tyres worn on inside and outside edges

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Tyres under-inflated (“Weekly checks”).

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Worn shock absorbers (Chapters 1 and 10).

Tyres worn unevenly

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Tyres out of balance (Chapter 1).

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Excessive wheel or tyre run-out (Chapter 1).

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Worn shock absorbers (Chapters 1 and 10).

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Faulty tyre (“Weekly checks”).

10 Electrical system

Note: For problems associated with the starting system, refer to the faults listed under “Engine” earlier in this Section.

Battery will not hold a charge 
for more than a few days

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Battery defective internally (Chapter 5).

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Battery electrolyte level low - where applicable 
(“Weekly checks”).

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Battery terminal connections loose or corroded 
(“Weekly checks”).

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Auxiliary drivebelt worn - or incorrectly adjusted (Chapter 1).

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Alternator not charging at correct output (Chapter 5).

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Alternator or voltage regulator faulty (Chapter 5).

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Short-circuit causing continual battery drain (Chapters 5 and 12).

Ignition/no-charge warning light remains
illuminated with engine running

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Auxiliary drivebelt broken, worn, or incorrectly adjusted 
(Chapter 1).

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Alternator brushes worn, sticking, or dirty (Chapter 5).

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Alternator brush springs weak or broken (Chapter 5).

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Internal fault in alternator or voltage regulator (Chapter 5).

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Broken, disconnected, or loose wiring in charging circuit
(Chapter 5).

Ignition/no-charge warning light fails to come on

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Warning light bulb blown (“Weekly checks”).

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Broken, disconnected, or loose wiring in warning light circuit
(Chapter 12).

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Alternator faulty (Chapter 5).

Lights inoperative

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Bulb blown (Chapter 12).

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Corrosion of bulb or bulbholder contacts (Chapter 12).

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Blown fuse (Chapter 12).

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Faulty relay (Chapter 12).

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Broken, loose, or disconnected wiring (Chapter 12).

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Faulty switch (Chapter 12).

Instrument readings inaccurate or erratic

Instrument readings increase with engine speed

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Faulty voltage regulator (Chapter 12).

Fuel or temperature gauges give no reading

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Faulty gauge sender unit (Chapters 3 and 4A or 4B).

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Wiring open-circuit (Chapter 12).

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Faulty gauge (Chapter 12).

Fuel or temperature gauges 
give continuous maximum reading

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Faulty gauge sender unit (Chapters 3 and 4A or 4B).

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Wiring short-circuit (Chapter 12).

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Faulty gauge (Chapter 12).

Horn inoperative, or unsatisfactory in operation

Horn operates all the time

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Horn contacts permanently bridged or horn push stuck down
(Chapter 12).

Horn fails to operate

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Blown fuse (Chapter 12).

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Cable or cable connections loose, broken or disconnected
(Chapter 12).

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Faulty horn (Chapter 12).

Horn emits intermittent or unsatisfactory sound

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Cable connections loose (Chapter 12).

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Horn mountings loose (Chapter 12).

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Faulty horn (Chapter 12).

Windscreen/tailgate wipers inoperative, or
unsatisfactory in operation

Wipers fail to operate, or operate very slowly

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Wiper blades stuck to screen, or linkage seized or binding
(Chapters 1 and 12).

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Blown fuse (Chapter 12).

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Cable or cable connections loose, broken or disconnected
(Chapter 12).

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Faulty relay (Chapter 12).

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Faulty wiper motor (Chapter 12).

Wiper blades sweep over 
too large or too small an area of the glass

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Wiper arms incorrectly positioned on spindles (Chapter 1).

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Excessive wear of wiper linkage (Chapter 12).

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Wiper motor or linkage mountings loose or insecure 
(Chapter 12).

Wiper blades fail to clean the glass effectively

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Wiper blade rubbers worn or perished (“Weekly checks”).

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Wiper arm tension springs broken, or arm pivots seized 
(Chapter 12).

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Insufficient windscreen washer additive to adequately remove
road film (“Weekly checks”).