Peugeot 405 Manual

Rear brake shoes - renewal
Braking system / 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 donТt 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 Remove the brake drum (see Section 9).

2 Working carefully, and taking the necessary precautions, remove all traces of brake dust from the brake drum, backplate and shoes.

3 Measure the thickness of the friction material of each brake shoe at several points; if either shoe is worn at any point to the specified minimum thickness or less, all four shoes must be renewed as a set. The shoes should also be renewed if any are fouled with oil or grease; there is no satisfactory way of degreasing friction material, once contaminated.

4 If any of the brake shoes are worn unevenly, or fouled with oil or grease, trace and rectify the cause before reassembly.

5 To renew the brake shoes, proceed as described under the relevant sub-heading.

Bendix brake shoes
Note: The components encountered may vary in detail, but the principles described in the following paragraphs are equally applicable to all models. Make a careful note of the fitted positions of all components before dismantling.

6 On early models, unhook the shoe retainer springs from the brake backplate using a forked tool similar to that shown. The tool can be improvised using a screwdriver with a notch in the blade. The tool is pushed through the centre of the spring, and the spring hook can then be released from the backplate (see illustrations).

6.6a Forked tool for removing early type Bendix shoe retainer springs
6.6a Forked tool for removing early type Bendix shoe retainer springs

6.6b Removing an early type Bendix shoe retainer spring
6.6b Removing an early type Bendix shoe retainer spring

7 On later models, using a pair of pliers, remove the shoe retainer spring cups by depressing and turning them through 90Ї (see illustration). With the cups removed, lift off the springs and withdraw the retainer pins.

6.7 Removing a later type Bendix shoe retainer spring
6.7 Removing a later type Bendix shoe retainer spring

8 Ease the shoes out one at a time from the lower pivot point, to release the tension of the return spring, then disconnect the lower return spring from both shoes (see illustration).

6.8 Ease the shoes out of the lower pivot point, and disconnect the lower
6.8 Ease the shoes out of the lower pivot point, and disconnect the lower return spring - Bendix rear brakes

9 Ease the upper end of both shoes out from their wheel cylinder locations, taking care not to damage the wheel cylinder seals, and disconnect the handbrake cable from the trailing shoe (see Haynes Hint). The brake shoe and adjuster strut assembly can then be manoeuvred out of position and away from the backplate. Do not depress the brake pedal until the brakes are reassembled.

10 With the shoe and adjuster strut assembly on a bench, make a note of the correct fitted positions of the springs and adjuster strut, to use as a guide on reassembly. Release the handbrake lever stop-peg (if not already done), then carefully detach the adjuster strut bolt retaining spring from the leading shoe.

Disconnect the upper return spring, then detach the leading shoe and return spring from the trailing shoe and strut assembly.

Unhook the spring securing the adjuster strut to the trailing shoe, and separate the two.

11 If genuine Peugeot brake shoes are being installed, it will be necessary to remove the handbrake lever from the original trailing shoe, and install it on the new shoe. Secure the lever in position with a new retaining clip. All return springs should be renewed, regardless of their apparent condition; spring kits are also available from Peugeot dealers.

12 Withdraw the adjuster bolt from the strut, and carefully examine the assembly for signs of wear or damage. Pay particular attention to the threads of the adjuster bolt and the knurled adjuster wheel, and renew if necessary. Note that left-hand and right-hand struts are not interchangeable - they are marked УGФ (gauche) and УDФ (droit) respectively. Also note that the strut adjuster bolts are not interchangeable; the left-hand strut bolt has a left-handed thread, and the right-hand bolt a right-handed thread.

13 Ensure that the components on the end of the strut are correctly positioned, then apply a little high-melting-point grease to the threads of the adjuster bolt (see illustration). Screw the adjuster wheel onto the bolt until only a small gap exists between the wheel and the head of the bolt, then install the bolt in the strut.

6.13 Correct fitted position of later type Bendix adjuster strut components
6.13 Correct fitted position of later type Bendix adjuster strut components

14 Fit the adjuster strut retaining spring to the trailing shoe, ensuring that the shorter hook of the spring is engaged with the shoe.

Attach the adjuster strut to the spring end, then ease the strut into position in its slot in the trailing shoe.

15 Engage the upper return spring with the trailing shoe, then hook the leading shoe onto the other end of the spring, and lever the leading shoe down until the adjuster bolt head is correctly located in its groove. Once the bolt is correctly located, hook its retaining spring into the slot on the leading shoe.

16 Peel back the rubber protective caps, and check the wheel cylinder for fluid leaks or other damage; check that both cylinder pistons are free to move easily. Refer to Section 12, if necessary, for information on wheel cylinder renewal.

17 Prior to installation, clean the backplate, and apply a smear of high-temperature brake grease or anti-seize compound to all those surfaces of the backplate which bear on the shoes, particularly the wheel cylinder pistons and lower pivot point (see illustration). Do not allow the lubricant to foul the friction material.

6.17 Apply high-melting-point grease to the shoe contact points on the
6.17 Apply high-melting-point grease to the shoe contact points on the backplate

18 Ensure that the handbrake lever stop-peg is correctly located against the edge of the trailing shoe, and remove the elastic band or cable-tie (as applicable) fitted to the wheel cylinder.

19 Manoeuvre the shoe and strut assembly into position on the vehicle, and engage the upper end of both shoes with the wheel cylinder pistons. Attach the handbrake cable to the trailing shoe lever. Fit the lower return spring to both shoes, and ease the shoes into position on the lower pivot point (see illustrations).

6.19a Fitting the brake shoes - early type Bendix brakes
6.19a Fitting the brake shoes - early type Bendix brakes

6.19b Rear view of early type Bendix shoe assembly correctly assembled -
6.19b Rear view of early type Bendix shoe assembly correctly assembled - removed from backplate for clarity

6.19c Front view of early type Bendix shoe assembly correctly assembled -
6.19c Front view of early type Bendix shoe assembly correctly assembled - removed from backplate for clarity

6.19d Later type Bendix shoe components correctly assembled
6.19d Later type Bendix shoe components correctly assembled

A Leading shoe
B Trailing shoe
C Lower pivot point
F Adjuster strut mechanism 1 Upper return spring
2 Lower return spring
3 Retaining pin, spring, spring cup 4 Adjuster strut-totrailing shoe spring

20 Tap the shoes to centralise them with the backplate, then refit the shoe retainer pins and springs, and secure them in position with the spring cups.

21 Using a screwdriver, turn the strut adjuster wheel to expand the shoes until the brake drum just slides over the shoes.

22 Refit the brake drum as described in Section 9.

23 Repeat the above procedure on the remaining rear brake.

24 Once both sets of rear shoes have been renewed, adjust the lining-to-drum clearance by repeatedly depressing the brake pedal.

Whilst depressing the pedal, have an assistant listen to the rear drums, to check that the adjuster strut is functioning correctly; if so, a clicking sound will be emitted by the strut as the pedal is depressed.

25 Check and, if necessary, adjust the handbrake as described in Section 17.

26 On completion, check the hydraulic fluid level as described in Chapter 1.

Girling brake shoes
27 Make a note of the correct fitted positions of the springs and adjuster strut, to use as a guide on reassembly (see illustration).

6.27 Correct fitted positions of Girling rear brake components
6.27 Correct fitted positions of Girling rear brake components

Arrow indicates direction of wheel rotation

28 Carefully unhook both the upper and lower return springs, and remove them from the brake shoes.

29 Using a pair of pliers, remove the leading shoe retainer spring cup by depressing it and turning through 90Ї. With the cup removed, lift off the spring, then withdraw the retainer pin and remove the shoe from the backplate.

Unhook the adjusting lever spring, and remove it from the leading shoe.

30 Detach the adjuster strut, and remove it from the trailing shoe.

31 Remove the trailing shoe retainer spring cup, spring and pin as described above, then detach the handbrake cable and remove the shoe from the vehicle. Do not depress the brake pedal until the brakes are reassembled.

32 If genuine Peugeot brake shoes are being installed, it will be necessary to remove the adjusting lever from the original leading shoe, and install it on the new shoe. All return springs should be renewed, regardless of their apparent condition; spring kits are also available from Peugeot dealers.

33 Withdraw the forked end from the adjuster strut, and carefully examine the assembly for signs of wear or damage. Pay particular attention to the threads and the knurled adjuster wheel, and renew if necessary. Note that left-hand and right-hand struts are not interchangeable; the left-hand fork has a lefthanded thread, and the right-hand fork a right-handed thread.

34 Peel back the rubber protective caps, and check the wheel cylinder for fluid leaks or other damage; check that both cylinder pistons are free to move easily. Refer to Section 12, if necessary, for information on wheel cylinder renewal.

35 Prior to installation, clean the backplate, and apply a thin smear of high-temperature brake grease or anti-seize compound to all those surfaces of the backplate which bear on the shoes, particularly the wheel cylinder pistons and lower pivot point. Do not allow the lubricant to foul the friction material.

36 Ensure that the handbrake lever stop-peg is correctly located against the edge of the trailing shoe, and remove the elastic band or cable-tie (as applicable) fitted to the wheel cylinder.

37 Locate the upper end of the trailing shoe in the wheel cylinder piston, then refit the retainer pin and spring, and secure it in position with the spring cup. Connect the handbrake cable to the lever.

38 Screw in the adjuster wheel until the minimum strut length is obtained, then hook the strut into position on the trailing shoe (note that the left and right-hand adjusters are not interchangeable - see paragraph 33).

Rotate the adjuster strut forked end, so that the cut-out of the fork will engage with the leading shoe adjusting lever once the shoe is installed (see illustration).

6.38 On Girling rear brake shoes, adjuster strut fork cut-out (A) must engage
6.38 On Girling rear brake shoes, adjuster strut fork cut-out (A) must engage with leading shoe adjusting lever on refitting

39 Fit the spring to the leading shoe adjusting lever, so that the shorter hook of the spring engages with the lever.

40 Slide the leading shoe assembly into position, ensuring that it is correctly engaged with the adjuster strut fork, and that the fork cut-out is engaged with the adjusting lever.

Ensure that the upper end of the shoe is located in the wheel cylinder piston, then secure the shoe in position with the retainer pin, spring and spring cup.

41 Install the upper and lower return springs, then tap the shoes to centralise them with the backplate.

42 Using a screwdriver, turn the strut adjuster wheel to expand the shoes until the brake drum just slides over the shoes.

43 Refit the brake drum as described in Section 9.

44 Repeat the above procedure on the remaining rear brake.

45 Once both sets of rear shoes have been renewed, adjust the lining-to-drum clearance by repeatedly depressing the brake pedal.

Whilst depressing the pedal, have an assistant listen to the rear drums, to check that the adjuster strut is functioning correctly; if so, a clicking sound will be emitted by the strut as the pedal is depressed.

46 Check and, if necessary, adjust the handbrake as described in Section 17.

47 On completion, check the hydraulic fluid level as described in Chapter 1.

All shoes
48 New shoes 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 shoe renewal.


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