Peugeot 405 Manual

Front brake pads - renewal
Braking system / Front brake pads - renewal


Warning: Renew both sets of front brake pads at the same time - never renew the pads on only one wheel, as uneven braking may result. Note that the dust created by wear of the pads may contain asbestos, which is a health hazard. Never blow it out with compressed air, and dont 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.

1 Apply the handbrake, then jack up the front of the vehicle and support it on axle stands (see Jacking and Vehicle Support). Remove the front roadwheels.

2 Trace the brake pad wear sensor wiring back from the pads, and disconnect it from the wiring connector (see illustration). Note the routing of the wiring, and free it from any relevant retaining clips.

4.2 Disconnecting the pad wear sensor wiring connector
4.2 Disconnecting the pad wear sensor wiring connector

3 Push the piston into its bore by pulling the caliper outwards.

4 There are two different types of front brake caliper fitted to the models covered in this manual as follows.

a) Models with solid front discs - Bendix calipers.

b) Models with ventilated front discs - Girling calipers.

Bendix caliper
Note: A new pad retaining plate spring clip should be used on refitting.

5 Using pliers, extract the small spring clip from the pad retaining plate, and then slide the plate out of the caliper (see illustrations).

4.5a Extract the spring clip (arrowed) . . .
4.5a Extract the spring clip (arrowed) . . .

4.5b . . . then slide the pad retaining plate from the caliper - Bendix
4.5b . . . then slide the pad retaining plate from the caliper - Bendix caliper

6 Withdraw the pads from the caliper, then make a note of the correct fitted position of each anti-rattle spring, and remove the spring from each pad (see illustration).

4.6 Withdrawing the outer brake pad - Bendix caliper
4.6 Withdrawing the outer brake pad - Bendix caliper

7 First measure the thickness of each brake pads friction material (see illustration).

4.7 Measuring brake pad friction material thickness
4.7 Measuring brake pad friction material thickness

If either pad is worn at any point to the specified minimum thickness or less, all four pads must be renewed. Also, the pads should be renewed if any are fouled with oil or grease; as there is no satisfactory way of degreasing friction material, once contaminated. If any of the brake pads are worn unevenly, or are fouled with oil or grease, trace and rectify the cause before reassembly. New brake pads and spring kits are available from Peugeot dealers.

8 If the brake pads are still serviceable, carefully clean them using a clean, fine wire brush or similar, paying particular attention to the sides and back of the metal backing. Clean out the grooves in the friction material, and pick out any large embedded particles of dirt or debris. Carefully clean the pad locations in the caliper body/mounting bracket.

9 Prior to fitting the pads, check that the guide pins are free to slide easily in the caliper body/mounting bracket, and check that the rubber guide pin gaiters are undamaged.

Brush the dust and dirt from the caliper and piston, but do not inhale it, as it is injurious to health. Inspect the dust seal around the piston for damage, and the piston for evidence of fluid leaks, corrosion or damage. If attention to any of these components is necessary, refer to Section 10.

10 If new brake pads are to be fitted, the caliper piston must be pushed back into the cylinder to make room for them. Either use a G-clamp or similar tool, or use suitable pieces of wood as levers. Provided that the master cylinder reservoir has not been overfilled with hydraulic fluid, there should be no spillage, but keep a careful watch on the fluid level while retracting the piston. If the fluid level rises above the MAX level line at any time, the surplus should be siphoned off or ejected via a plastic tube connected to the bleed screw (see Section 2). Note: Do not syphon the fluid by mouth, as it is poisonous; use a syringe or an old poultry baster.

11 Fit the anti-rattle springs to the pads, so that when the pads are installed in the caliper, the spring end will be located at the opposite end of the pad in relation to the pad retaining plate.

12 Locate the pads in the caliper, ensuring that the friction material of each pad is against the brake disc, and check that the anti-rattle spring ends are at the opposite end of the pad to which the retaining plate is to be inserted.

Note that if the pads are installed correctly, looking at the pads from the front of the vehicle, the innermost pad groove must be higher than the outer pad groove. Ensure that the pads are fitted correctly before proceeding (see illustrations).

4.12a Correct location of the anti-rattle springs on Bendix brake pads
4.12a Correct location of the anti-rattle springs on Bendix brake pads

4.12b Correct fitting of brake pads - Bendix caliper
4.12b Correct fitting of brake pads - Bendix caliper

B Grooves
D Pad retaining plate spring clip V Bleed screw

13 Slide the retaining plate into place, and install the new small spring clip at its inner end. It may be necessary to file an entry chamfer on the edge of the retaining plate, to enable it to be fitted without difficulty.

14 Reconnect the brake pad wear sensor wiring connectors, ensuring that the outer wire is correctly routed through the anti-rattle spring loops, and that both wires pass through the loop of the bleed screw cap.

15 Depress the brake pedal repeatedly, until the pads are pressed into firm contact with the brake disc, and normal (non-assisted) pedal pressure is restored.

16 Repeat the above procedure on the remaining front brake caliper.

17 Refit the roadwheels, then lower the vehicle to the ground and tighten the roadwheel bolts to the specified torque setting.

18 Check the hydraulic fluid level as described in Weekly Checks.

Girling caliper
Note: A new lower guide pin bolt must be used on refitting.

19 Where applicable, prise off the dust cover, then slacken and remove the lower caliper guide pin bolt, using a slim open-ended spanner to prevent the guide pin itself from rotating (see illustration). Discard the guide pin bolt - a new bolt must be used on refitting.

4.19 Hold the pin guide pin with an openended spanner while slackening the
4.19 Hold the pin guide pin with an openended spanner while slackening the guide pin bolt - Girling caliper

20 With the lower guide pin bolt removed, pivot the caliper upwards, away from the brake pads and mounting bracket, taking care not to strain the flexible brake hose (see illustration).

4.20 Pivot the caliper upwards away from the brake pads - Girling caliper
4.20 Pivot the caliper upwards away from the brake pads - Girling caliper

21 Withdraw the two brake pads from the caliper mounting bracket, and examine them as described above in paragraphs 7 to 10.

22 Apply a little brake grease to the rear of the pads, then Install the pads in the caliper mounting bracket, ensuring that the friction material of each pad is against the brake disc (see illustration).

4.22 Ensure that the brake pads are fitted the correct way around, with
4.22 Ensure that the brake pads are fitted the correct way around, with friction material facing the disc . . .

23 Position the caliper over the pads, and pass the pad warning sensor wiring through the caliper aperture and underneath the retaining clip (see illustration).

4.23 . . . then refit the caliper, feeding the pad wiring through the caliper
4.23 . . . then refit the caliper, feeding the pad wiring through the caliper aperture

If the threadsof the new guide pin bolt are not already precoated with locking compound, apply a suitable thread-locking compound to them.

Pivot the caliper into position, then install the guide pin bolt, tightening to the specified torque setting while retaining the guide pin with an open-ended spanner. Where applicable, refit the dust cover to the guide pin.

24 Reconnect the brake pad wear sensor wiring connector, ensuring that the wiring is correctly routed through the loop of the caliper bleed screw cap.

25 Depress the brake pedal repeatedly, until the pads are pressed into firm contact with the brake disc, and normal (non-assisted) pedal pressure is restored.

26 Repeat the procedure on the remaining front brake caliper.

27 Refit the roadwheels, then lower the vehicle to the ground and tighten the roadwheel bolts to the specified torque setting.

28 Check the hydraulic fluid level as described in Chapter 1.

All calipers
29 New pads will not give full braking efficiency until they have bedded in. Be prepared for this, and avoid hard braking as far as possible for the first hundred miles or so after pad renewal.


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