Peugeot 405 Manual

Front brake disc - inspection, removal and refitting
Braking system / Front brake disc - inspection, removal and refitting


Note: Before starting work, refer to the note at the beginning of Section 4 concerning the dangers of asbestos dust.

Inspection
Note: If either disc requires renewal, BOTH should be renewed at the same time, to ensure even and consistent braking. New brake pads should also be fitted.

1 Apply the handbrake, then jack up the front of the car and support it on axle stands (see УJacking and Vehicle SupportФ). Remove the appropriate front roadwheel.

2 Slowly rotate the brake disc so that the full area of both sides can be checked; remove the brake pads if better access is required to the inboard surface. Light scoring is normal in the area swept by the brake pads, but if heavy scoring or cracks are found, the disc must be renewed.

3 It is normal to find a lip of rust and brake dust around the discТs perimeter; this can be scraped off if required. If, however, a lip has formed due to excessive wear of the brake pad swept area, then the discТs thickness must be measured using a micrometer (see illustration).

7.3 Using a micrometer to measure disc thickness
7.3 Using a micrometer to measure disc thickness

Take measurements at several places around the disc, at the inside and outside of the pad swept area; if the disc has worn at any point to the specified minimum thickness or less, the disc must be renewed.

4 If the disc is thought to be warped, it can be checked for run-out. Either use a dial gauge mounted on any convenient fixed point, while the disc is slowly rotated, or use feeler blades to measure (at several points all around the disc) the clearance between the disc and a fixed point, such as the caliper mounting bracket (see illustration).

7.4 Checking disc run-out using a dial gauge
7.4 Checking disc run-out using a dial gauge

If the measurements
obtained are at the specified maximum or beyond, the disc is excessively warped, and must be renewed; however, it is worth checking first that the hub bearing is in good condition (Chapters 1 and/or 10). Also try the effect of removing the disc and turning it through 180Ї, to reposition it on the hub; if the run-out is still excessive, the disc must be renewed.

5 Check the disc for cracks, especially around the wheel bolt holes, and any other wear or damage, and renew if necessary.

Removal
6 On models with Bendix calipers, remove the brake pads as described in Section 4.

7 On models with Girling calipers, unscrew the two bolts securing the caliper mounting bracket to the hub carrier (see illustration).

7.7 Removing a Girling caliper mounting bracket bolt
7.7 Removing a Girling caliper mounting bracket bolt

Using a piece of wire or string, tie the caliper to the front suspension coil spring, to avoid placing any strain on the fluid hose.

8 Use chalk or paint to mark the relationship of the disc to the hub, then remove the screw(s) securing the brake disc to the hub, and remove the disc (see illustration). If it is tight, lightly tap its rear face with a hide or plastic mallet.

7.8 Disc securing screws (arrowed)
7.8 Disc securing screws (arrowed)

Refitting
9 Refitting is the reverse of the removal procedure, noting the following points: a) Ensure that the mating surfaces of the disc and hub are clean and flat.

b) Align (if applicable) the marks made on removal, and securely tighten the disc retaining screws.

c) If a new disc has been fitted, use a suitable solvent to wipe any preservative coating from the disc, before refitting the caliper.

d) On models with Girling calipers, refit the caliper as described in Section 10.

e) On models with Bendix calipers, refit the pads as described in Section 4.

f) Refit the roadwheel, then lower the vehicle to the ground and tighten the roadwheel bolts to the specified torque.

On completion, repeatedly depress the brake pedal until normal (non-assisted) pedal pressure returns.


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