Peugeot 405 Manual

Rear brake pads - renewal
Braking system / Rear brake pads - renewal


Warning: Renew both sets of rear 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.

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

1 Chock the front wheels, then jack up the rear of the vehicle and support securely on axle stands (see Jacking and Vehicle Support). Remove the rear roadwheels.

2 Disconnect the handbrake cable end from the operating lever on the caliper.

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

4 With the upper guide pin bolt removed, pivot the caliper downwards, away from the brake pads and mounting bracket, taking care not to strain the flexible brake hose.

5 Withdraw the brake pads from the caliper mounting bracket.

6 First measure the thickness of each brake pads friction material. 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; 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 are available from Peugeot dealers.

7 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. Pick out any large embedded particles of dirt or debris from the friction material. Carefully clean the pad locations in the caliper body/mounting bracket.

8 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 is necessary, see Section 11.

9 If new brake pads are to be fitted, the caliper piston must be pushed back into the cylinder to make room for them. 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.

10 Retract the caliper piston by applying pressure, and turning it clockwise. A special tool is available for this purpose but a pair of circlip pliers or any similar tool can be used instead. Take care not to damage the surface of the piston. Turn the piston to position the notches in the piston on the centreline of the slot in the front of the caliper.

11 Fit the pads, sliding them into position in the caliper bracket, with the friction material against the disc.

12 If the threads of the new guide pin bolt are not already pre-coated 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.

13 Reconnect the handbrake cable to the caliper.

14 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.

15 Repeat the procedure on the remaining rear caliper.

16 Refit the roadwheels, then lower the vehicle to the ground.

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

18 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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