Peugeot 205 (954 cc, 1124 cc, 1360 cc, 1580 cc & 1905 cc). Manual - part 19

5B•8

Notes

Chapter 9
Braking system

System type:

Footbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dual-circuit hydraulic with servo assistance on all non-basic models.
Anti-lock braking (ABS) optional on certain later models.

Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical by cables to rear brakes

Front brakes

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solid or ventilated disc, with single piston sliding calipers

Brake pad minimum lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 mm

Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

247 mm

Disc thickness:

New:

Non-ventilated disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.0 mm

Ventilated disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20.4 mm

Minimum after resurfacing:

Non-ventilated disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5 mm

Ventilated disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18.9 mm

Maximum disc run out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.07 mm

Rear drum brakes

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Self-adjusting drum with leading and trailing shoes

Brake shoe minimum lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0 mm

Drum internal diameter:

New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180.0 mm

Maximum after resurfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181.0 mm

Drum out-of-round (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.10 mm

Rear disc brakes

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disc, with single piston sliding calipers

Brake pad minimum lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 mm

Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

247 mm

Disc thickness:

New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.0 mm

Minimum after resurfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.0 mm

Maximum disc run out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.07 mm

Anti-lock braking system (ABS) - general information . . . . . . . . . . . . 19
Anti-lock braking system (ABS) components - removal and refitting 20
Brake disc - inspection, removal and refitting  . . . . . . . . . . . . . . . . . . 9
Brake fluid level check  . . . . . . . . . . . . . . . . . . . . .See “Weekly checks”
Brake fluid renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Brake pad wear check . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Brake pedal - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Front brake caliper - removal, overhaul and refitting . . . . . . . . . . . . . 7
Front brake pads - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General information  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Handbrake - adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Handbrake cables - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Handbrake lever - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic pipes and hoses - renewal  . . . . . . . . . . . . . . . . . . . . . . . . 3

Hydraulic system - bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Master cylinder - removal, overhaul and refitting . . . . . . . . . . . . . . . 12
Rear brake caliper (1.9 GTI models) - removal, overhaul

and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Rear brake compensator (GTI models) - general information, removal

and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Rear brake hub/drum - removal, inspection and refitting  . . . . . . . . . 11
Rear brake pads (1.9 GTI models) - renewal  . . . . . . . . . . . . . . . . . . . 6
Rear brake shoes - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear brake shoe wear check  . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Rear wheel cylinder - removal, overhaul and refitting  . . . . . . . . . . . . 10
Underbody and fuel/brake line check  . . . . . . . . . . . . . . .See Chapter 1
Vacuum servo unit - testing, removal and refitting  . . . . . . . . . . . . . . 14

9•1

Specifications

Contents

Easy, suitable for
novice with little
experience

Fairly easy, suitable
for beginner with
some experience

Fairly difficult,
suitable for competent
DIY mechanic

Difficult, suitable for
experienced DIY
mechanic

Very difficult,
suitable for expert DIY
or professional

Degrees of difficulty

Torque wrench settings

lbf ft

Girling front caliper mounting bolts:

All models except 1.9 GTI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.9 GTI models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100

Girling front caliper guide bolts (1.9 GTI models) . . . . . . . . . . . . . . . . . .

DBA Bendix front caliper mounting bolts . . . . . . . . . . . . . . . . . . . . . . . .

120

Rear caliper mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120

Rear backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear hub nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215

159

General information

The braking system is of hydraulic type with

the front disc brakes and rear drum brakes on
all except 1.9 GTI models. On these vehicles
disc brakes are also fitted at the rear. On all
models, the handbrake is cable-operated on
the rear wheels.

The hydraulic system is split into two

circuits, so that in the event of failure of one
circuit, the other will still provide adequate
braking power (although pedal travel and
effort may increase). The hydraulic circuits are
split either diagonally or front-to-rear
according to model. In the diagonally split
system, each hydraulic circuit supplies one
front, and one diagonally opposite rear brake.
In the front-to-rear arrangement, one circuit
serves the front brakes and the other circuit
the rear brakes.

A compensating valve (or valves) reduces

the hydraulic pressure to the rear brakes
under heavy applications of the brake pedal in
order to prevent rear wheel lock-up.

A vacuum servo unit is fitted to all

non-basic models.

From 1991, the Bendix anti-lock braking

system (ABS) is available as an option on
certain models and is described in further
detail in Section 19.
Note: When servicing any part of the system,
work carefully and methodically; also observe
scrupulous cleanliness when overhauling any
part of the hydraulic system. Always renew
components (in axle sets, where applicable) if
in doubt about their condition, and use only
genuine Peugeot replacement parts, or at
least those of known good quality. Note the
warnings given in “Safety first” and at relevant
points in this Chapter concerning the dangers
of asbestos dust and hydraulic fluid.

Hydraulic system - bleeding

Warning: Hydraulic fluid is
poisonous; wash off immediately
and thoroughly in the case of
skin contact, and seek

immediate medical advice if any fluid is
swallowed or gets into the eyes. Certain
types of hydraulic fluid are inflammable,

and may ignite when allowed into contact
with hot components; when servicing any
hydraulic system, it is safest to assume that
the fluid IS inflammable, and to take
precautions against the risk of fire as
though it is petrol that is being handled.
Hydraulic fluid is also an effective paint
stripper, and will attack plastics; if any is
spilt, it should be washed off immediately,
using copious quantities of clean water.
Finally, it is hygroscopic (it absorbs
moisture from the air). The more moisture
is absorbed by the fluid, the lower its
boiling point becomes, leading to a
dangerous loss of braking under hard use.
Old fluid may be contaminated and unfit for
further use. When topping-up or renewing
the fluid, always use the recommended
type, and ensure that it comes from a
freshly-opened sealed container.

General

1 The correct functioning of the brake
hydraulic system is only possible after
removing all air from the components and
circuit; this is achieved by bleeding the
system.
2 During the bleeding procedure, add only
clean, fresh hydraulic fluid of the specified
type; never re-use fluid that has already been
bled from the system. Ensure that sufficient
fluid is available before starting work.
3 If there is any possibility of incorrect fluid
being used in the system, the brake lines and
components must be completely flushed with
uncontaminated fluid and new seals fitted to
the components.
4 If brake fluid has been lost from the master
cylinder due to a leak in the system, ensure
that the cause is traced and rectified before
proceeding further.
5 Park the car on level ground, switch off the
ignition and select first gear (manual
transmission) or Park (automatic transmission)
then chock the wheels and release the
handbrake.
6 Check that all pipes and hoses are secure,
unions tight, and bleed screws closed.
Remove the dust caps and clean any dirt from
around the bleed screws.
7 Unscrew the master cylinder reservoir cap,
and top-up the reservoir to the “MAX” level
line. Refit the cap loosely, and remember to
maintain the fluid level at least above the
“MIN” level line throughout the procedure,
otherwise there is a risk of further air entering
the system.

8 There are a number of one-man, do-it-
yourself, brake bleeding kits currently
available from motor accessory shops. It is
recommended that one of these kits is used
wherever possible, as they greatly simplify the
bleeding operation, and also reduce the risk
of expelled air and fluid being drawn back into
the system. If such a kit is not available, the
basic (two-man) method must be used, which
is described in detail below.
9 If a kit is to be used, prepare the car as
described previously, and follow the kit
manufacturer’s instructions, as the procedure
may vary slightly according to the type being
used; generally, they are as outlined below in
the relevant sub-section.
10 Whichever method is used, the same
sequence must be followed (paragraphs 11
and 12) to ensure the removal of all air from
the system.

Bleeding sequence

11 If the hydraulic system has only been
partially disconnected and suitable precautions
were taken to minimise fluid loss, it should only
be necessary to bleed that part of the system
(ie the primary or secondary circuit).
12 If the complete system is to be bled, then
it should be done in the following sequence:

Non-ABS models:

Diagonally split system - all models except 1.6
GTI:

RH rear wheel
LH front wheel
LH rear wheel
RH front wheel

Front-to-rear split system - 1.6 GTI models:

LH rear wheel and inertia compensator
RH rear wheel
LH front wheel
RH front wheel

ABS models:

Note: Before carrying out any bleeding, the
battery negative lead must be disconnected,
and the brown three-way, brown five-way and
green five-way wiring connectors must be
disconnected from the regulator unit to
prevent the possibility of air entering the
system. The connectors must not be
reconnected until the hydraulic system has
been bled.

LH rear wheel
RH rear wheel
LH front wheel
RH front wheel
ABS regulator unit (see illustration)

9•2 Braking system

Bleeding - basic (two-man)
method

13 Collect a clean glass jar of reasonable size
and a suitable length of plastic or rubber
tubing, which is a tight fit over the bleed
screw, and a ring spanner to fit the screws.
The help of an assistant will also be required.
14 If not already done, remove the dust cap
from the bleed screw of the first wheel to be
bled and fit the spanner and bleed tube to the
screw (see illustration). Place the other end
of the tube in the jar, and pour in sufficient
fluid to cover the end of the tube.
15 Ensure that the master cylinder reservoir
fluid level is maintained at least above the
“MIN” level line throughout the procedure.
16 Have the assistant fully depress the brake
pedal several times to build up pressure, then
maintain it on the final downstroke.
17 While pedal pressure is maintained,
unscrew the bleed screw (approximately one
turn) and allow the compressed fluid and air to
flow into the jar. The assistant should maintain
pedal pressure, following it down to the floor if
necessary, and should not release it until
instructed to do so. When the flow stops,
tighten the bleed screw again have the
assistant release the pedal slowly, and
recheck the reservoir fluid level.
18 Repeat the steps given in paragraphs 16
and 17 until the fluid emerging from the bleed
screw is free from air bubbles. If the master
cylinder has been drained and refilled, and air
is being bled from the first screw in the

sequence, allow approximately five seconds
between cycles for the master cylinder
passages to refill.
19 On 1.6 GTI models only it is now
important to dislodge air trapped in the inertia
compensator. To do this, open the bleed
screw again and have your assistant fully
depress and release the brake pedal rapidly 4
or 5 times, finally keeping the pedal
depressed before tightening the bleed screw.
20 When no more air bubbles appear, tighten
the bleed screw securely, remove the tube
and spanner and refit the dust cap. Do not
overtighten the bleed screw.
21 Repeat these procedures on the
remaining brakes in sequence until all air is
removed from the system and the brake pedal
feels firm again.

Bleeding - using a one-way
valve kit

22 As their name implies, these kits consist of
a length of tubing with a one-way valve fitted,
to prevent expelled air and fluid being drawn
back into the system; some kits include a
translucent container, which can be positioned
so that the air bubbles can be more easily
seen flowing from the end of the tube.
23 The kit is connected to the bleed screw,
which is then opened. The user returns to the
driver’s seat, depresses the brake pedal with
a smooth steady stroke, and slowly releases
it; this is repeated until the expelled fluid is
clear of air bubbles. When using one of these
kits on 1.6 GTI models, remember to carry out
the procedure described in paragraph 19 after
bleeding the first brake in the sequence.
24 Note that these kits simplify work so
much that it is easy to forget the master
cylinder fluid level; ensure that this is
maintained at least above the “MIN” level line
at all times.

Bleeding - using a pressure-
bleeding kit

25 These kits are usually operated by the
reserve of pressurised air contained in the
spare tyre. However, note that it will probably
be necessary to reduce the pressure to a
lower level than normal; refer to the
instructions supplied with the kit.
26 By connecting a pressurised, fluid-filled
container to the master cylinder reservoir,
bleeding is then carried out by simply opening
each bleed screw in turn (in the specified
sequence) and allowing the fluid to run out,
until no more air bubbles can be seen in the
expelled fluid. When using one of these kits
on 1.6 GTI models, remember to carry out the
procedure described in paragraph 19 after
bleeding the first brake in the sequence.
27 This method has the advantage that the
large reservoir of fluid provides an additional
safeguard against air being drawn into the
system during bleeding.
28 Pressure bleeding is particularly effective
when bleeding “difficult” systems, or when
bleeding the complete system at the time of
routine fluid renewal.

All methods

29 When bleeding is complete, and firm
pedal feel is restored, wash off any spilt fluid,
tighten the bleed screws securely, and refit
their dust caps.
30 Check the hydraulic fluid level in the master
cylinder reservoir and top-up if necessary.
31 Discard any hydraulic fluid that has been
bled from the system; it will not be fit for re-use.
32 Check the feel of the brake pedal. If it feels
at all spongy, air must still be present in the
system, and further bleeding is required.
Failure to bleed satisfactorily after a reasonable
repetition of the bleeding operations may be
due to worn master cylinder seals.
33 On models with ABS, reconnect the wiring
connectors to the regulator unit and
reconnect the battery.

Braking system 9•3

2.12 Bleed screws (1 and 2) on ABS regulator unit

2.14 Bleed screw and dust cap on front

brake caliper

Hydraulic pipes and hoses -
renewal

Note: Before starting work, refer to the
warning at the beginning of Section 2
concerning the dangers of hydraulic fluid.
1 If any pipe or hose is to be renewed,
minimise hydraulic fluid loss by removing the
master cylinder reservoir cap, placing a piece
of plastic film over the reservoir and sealing it
with an elastic band. Alternatively, flexible
hoses can be sealed, if required, using a
proprietary brake hose clamp; metal brake
pipe unions can be plugged (if care is taken
not to allow dirt into the system) or capped
immediately they are disconnected. Place a
wad of rag under any union that is to be
disconnected, to catch any spilt fluid.
2 If a flexible hose is to be disconnected,
unscrew the brake pipe union nut before
removing the spring clip which secures the
hose to its mounting. Depending upon the
make of the particular caliper, the other end of
the hose may be connected simply by
screwing it into its tapped hole or by using a
hollow bolt with banjo end fitting. Use a new
copper sealing washer on each side of the
banjo union.
3 To unscrew the union nuts, it is preferable to
obtain a brake pipe spanner of the correct size;
these are available from most large motor
accessory shops. Failing this, a close-fitting
open-ended spanner will be required, though if
the nuts are tight or corroded, their flats may be
rounded-off if the spanner slips. In such a case,
a self-locking wrench is often the only way to
unscrew a stubborn union, but it follows that
the pipe and the damaged nuts must be
renewed on reassembly. Always clean a union
and surrounding area before disconnecting it. If
disconnecting a component with more than
one union, make a careful note of the
connections before disturbing any of them.
4 If a brake pipe is to be renewed, it can be
obtained, cut to length and with the union
nuts and end flares in place, from Peugeot
dealers. All that is then necessary is to bend it
to shape, following the line of the original,
before fitting it to the car. Alternatively, most
motor accessory shops can make up brake

pipes from kits, but this requires very careful
measurement of the original, to ensure that
the replacement is of the correct length. The
safest answer is usually to take the original to
the shop as a pattern.
5 Before refitting, blow through the new pipe
or hose with dry compressed air. Do not
overtighten the union nuts. It is not necessary
to exercise brute force to obtain a sound joint.
6 If flexible rubber hoses are renewed, ensure
that the pipes and hoses are correctly routed,
with no kinks or twists, and that they are
secured in the clips or brackets provided.
7 After fitting, bleed the hydraulic system as
described in Section 2, wash off any spilt
fluid, and check carefully for fluid leaks.

Front brake pads - renewal

Warning: Disc brake pads must
be renewed on both front
wheels at the same time - never
renew the pads on only one

wheel as uneven braking may result. Dust
created by wear of the pads may contain
asbestos, which is a health hazard. Never
blow it out with compressed air and do not
inhale any of it. DO NOT use petroleum-
based solvents to clean brake parts. Use
brake cleaner or methylated spirit only. DO
NOT allow any brake fluid, oil or grease to
contact the brake pads or disc. Also refer
to the warning at the start of Section 2
concerning the dangers of hydraulic fluid.

All models except 1.9 GTI

1 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and vehicle support”). Remove
the front roadwheels.
2 Note that two different types of brake
caliper may be fitted according to model and
year. Identify the type fitted, with reference to
the accompanying illustrations or the caliper
itself, then proceed as described under the
relevant sub-heading.

DBA Bendix caliper

3 Remove the clip from the end of the upper
sliding key. Disconnect the pad wear wiring
connector as necessary (see illustrations).
4 Pull out the upper sliding key (see
illustration).
5 Using a lever against the front suspension
strut, push the cylinder towards the brake disc
so that the outer pad can be withdrawn from
the caliper (see illustration).
6 Push back the caliper and withdraw the
inner pad (see illustration). Make a note of
the correct fitted position of the anti-rattle
springs and remove the spring from each pad.
7 Clean away all dust and dirt from the
caliper. Check for brake fluid leakage around
the piston dust seal and, if evident, overhaul
the caliper, as described later in this Chapter.
Check the brake disc for wear and also check
that the rubber bellows on the cylinder sliding
rods are in good condition.
8 Clean the backs of the brake pads and
apply a little anti-squeal brake grease. Also
apply the grease to the lower pad locating lip
of the caliper.

9•4 Braking system

4.3a Pad sliding key clip - arrowed

(DBA Bendix caliper)

4.3b Disconnecting the pad wear wiring

connector (DBA Bendix caliper)

4.4 Removing the pad sliding key

(DBA Bendix caliper)

4.5 Removing the outer pad

(DBA Bendix caliper)

4.6 Removing the inner pad

(DBA Bendix caliper)

9 With the caliper pushed inwards, insert the
inner pad then push the caliper outwards and
insert the outer pad. If offset pads are fitted, it
is important to fit these pads in the correct
positions as shown (see illustration). The
inner pads with pad wear wires must be
located at the top of the caliper.
10 Check that the pads are correctly
positioned on the caliper lip and with the anti-
rattle springs in place (see illustration) then
tap in the upper sliding key to lock them. Fit
the sliding key clip.

Girling caliper

11 Extract the spring clips and tap out the
pad retaining pins. Disconnect the pad wear
wiring as necessary (see illustration).
12 Lever the cylinder outwards and withdraw
the outer pad then push in the caliper and
withdraw the inner pad. Recover the anti-
squeal shims (if fitted) noting their positioning
with regards to the pad retaining pins - refer
to paragraph 14.
13 Clean and check the caliper, as described
in paragraph 7, then clean the backs of the

pads and apply a little anti-squeal brake
grease. Note that, as from early 1985, a
special spring is fitted to the inner pads to
prevent pad knock within the caliper. The
spring (obtainable from Peugeot dealers) may
be fitted to earlier models by tapping the inner
pad control rivet through the backing plate so
that the clip may be located on both sides
(see illustration).
14 With the caliper pushed inwards, insert
the inner pad then push the caliper outwards
and insert the outer pad. Note that from
chassis no 5 600 000, an anti-squeal shim
was fitted between the inner pads and the
caliper pistons, being located on both upper
and lower pad retaining pins. However, as

from chassis no 5 957 000, the shim was
modified, being located only on the lower pad
retaining pin (see illustrations). When fitting
the anti-squeal shims, the arrow cut-out must
face downwards (ie in the forward rotational
direction of the disc).
15 Tap in the pad retaining pins and fit the
spring clips.
16 Where fitted, hook the anti-knock spring
on the lower pad retaining pin.

1.9 GTI models

17 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and vehicle support”). Remove
the front roadwheels.

Braking system 9•5

4.11 Girling brake caliper and pad

arrangement

4.9 Correct orientation of offset brake pads viewed from front of

vehicle (DBA Bendix caliper)

4.10 Fitted position of the anti-rattle springs on the brake pads

(DBA Bendix caliper)

4.13 Method of fitting anti-knock spring to

Girling inner brake pad

1 Loop for rivet
2 Loop for lower retaining pin
3 Anti-knock spring

18 Disconnect the wire for the pad wear
warning light.
19 Hold the lower guide stationary with one
spanner, then unscrew the bolt (see
illustration).
20 Swivel the caliper upwards, then withdraw
the two brake pads from the caliper bracket
(see illustrations).
21 Clean and check the caliper, as described
in paragraph 7.
22 Push the piston fully into the cylinder.
23 Clean the backs of the pads, and apply a
little anti-squeal brake grease. Refit the inner
pad (with the pad wear warning wire), then the
outer pad.
24 Lower the caliper. Apply locking fluid to
the lower guide bolt, insert it, and tighten to
the specified torque while holding the guide
stationary with another spanner.
25 Reconnect the pad wear warning light
wire.

All calipers

26 Repeat the operations on the opposite
disc caliper.
27 Apply the footbrake several times to
position the pads against the discs.
28 Top-up the master cylinder reservoir to its
correct level.

29 Refit the roadwheels and lower the car to
the ground.
30 Note that if genuine Peugeot
replacements have been fitted, these pads
have a thin coating of abrasive material, which
cleans the disc during the initial applications
of the brakes. This coating also removes any
disc imperfections which would cause
steering vibration. After fitting these pads, the
brakes must be applied lightly and
intermittently for the first 3 miles (5 km), then
“bedded-in” for 120 miles (200 km), avoiding
heavy or prolonged braking wherever
possible.

Rear brake shoes - renewal

Warning: Brake shoes must be
renewed on both rear wheels at
the same time - never renew the
shoes on only one wheel, as

uneven braking may result. Also, the dust
created by wear of the shoes may contain
asbestos, which is a health hazard. Never
blow it out with compressed air, and don’t
inhale any of it. An approved filtering mask
should be worn when working on the

brakes. DO NOT use petrol or petroleum-
based solvents to clean brake parts; use
brake cleaner or methylated spirit only.
Note: The rear brake shoe assemblies may be
of either DBA Bendix or Girling manufacture,
according to model and year. The components
may vary in detail, but the principles described
in the following paragraphs are equally
applicable to both types. Make a careful note
of the fitted positions of all components before
dismantling.
1 Remove the relevant hub/drum as
described in Section 11.
2 Brush the dust and dirt from the shoes,
backplate and drum.
3 Note the position of each shoe and the
location of the return and steady springs (see
illustrations).
4 Unhook and remove the upper return spring
(see illustration).
5 Remove the steady springs using pliers to
depress the outer cups and turn them through
90° (see illustration). Remove the pins from
the backplate.
6 Move the serrated automatic adjuster lever
quadrant against spring tension (see
illustration), move the lever forwards and
release the strut from the top of the shoes
(DBA Bendix type only).

9•6 Braking system

4.14a Early type anti-squeal shim

(Girling caliper)

4.14b Later type anti-squeal shim

(Girling caliper)

4.19 Unscrewing the lower caliper guide

pin bolt (1.9 GTI)

4.20a Swivel the caliper upwards . . .

4.20b . . . then withdraw the two brake pads (1.9 GTI)

7 Expand the shoes over the wheel cylinder
then release them from the bottom anchor.
8 Unhook the lever return spring and the
handbrake cable.
9 If necessary, position a rubber band over
the wheel cylinder to prevent the pistons
coming out. Should there be evidence of brake
fluid leakage from the wheel cylinder, renew it
or overhaul it, as described in Section 10.
10 Transfer the handbrake and automatic
adjuster levers to the new shoes as required.
Note that the levers and strut on each rear
wheel are different, and that the leading and
trailing shoes are fitted with different grade
linings.
11 Place the shoes on the bench in their
correct location and fit the lower return spring.
12 Apply brake grease sparingly to the metal
contact points of the shoes, then position
them on the backplate and reconnect the
handbrake cable. Locate the shoe ends on
the bottom anchor.

13 Engage the strut with the slots at the top
of the shoes, making sure it is located
correctly on the automatic adjuster lever.
Engage the upper shoe ends on the wheel
cylinder pistons.
14 Insert the steady spring pins in the
backplate and through the shoe webs, then fit
the springs and outer cups.
15 Fit the upper return spring.
16 Move the serrated automatic adjuster
lever quadrant against the spring tension to
set the shoes at their minimum diameter.
17 Check that the handbrake lever on the
rear brake shoe is positioned with the lug on
the edge of the shoe web and not behind the
shoe.
18 Refit the hub/drum as described in
Section 11, but do not lower the car to the
ground at this stage.
19 Apply the footbrake several times to set
the shoes in their adjusted position.

20 Adjust the handbrake, as described in
Section 15.
21 Repeat all the operations on the opposite
rear brake then refit the roadwheels and lower
the car to the ground.

Rear brake pads (1.9 GTI
models) - renewal

Warning: Disc brake pads must
be renewed on both rear wheels
at the same time - never renew
the pads on only one wheel as

uneven braking may result. Dust created
by wear of the pads may contain asbestos,
which is a health hazard. Never blow it out
with compressed air and do not inhale any
of it. DO NOT use petroleum-based
solvents to clean brake parts. Use brake
cleaner or methylated spirit only. DO NOT
allow any brake fluid, oil or grease to

Braking system 9•7

5.4 Upper return spring location

(DBA Bendix type)

5.5 Shoe steady springs - arrowed

(DBA Bendix type)

5.6 Automatic adjuster lever - arrowed

(DBA Bendix type)

5.3b Girling type rear brake component layout

5.3a DBA Bendix type rear brake component layout

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