Peugeot 405 Manual

Front brake caliper - removal, overhaul and refitting
Braking system / Front brake caliper - removal, overhaul and refitting


Note: Before starting work, refer to the note at the beginning of Section 2 concerning the dangers of hydraulic fluid, and to the warning at the beginning of Section 4 concerning the dangers of asbestos dust.

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

2 Minimise fluid loss by first removing the master cylinder reservoir cap, and then tightening it down onto a piece of polythene, to obtain an airtight seal. Alternatively, use a brake hose clamp, a G-clamp or a similar tool to clamp the flexible hose (see illustration).

10.2 Using a clamp on the caliper hydraulic hose
10.2 Using a clamp on the caliper hydraulic hose

3 Remove the brake pads as described in Section 4.

4 Clean the area around the union, then loosen the fluid hose union nut.

5 Slacken the two bolts securing the caliper assembly to the hub carrier and remove them along with the mounting plate, noting which way around the plate is fitted. Lift the caliper assembly away from the brake disc, and unscrew it from the end of the fluid hose. Plug the open ends of the caliper and hose to prevent dirt ingress and fluid loss.

Overhaul
6 The caliper can be overhauled after obtaining the relevant repair kit from a Peugeot dealer. Ensure that the correct repair kit is obtained for the caliper being worked on.

Note the locations of all components to ensure correct refitting, and lubricate the new seals using clean brake fluid. Follow the assembly instructions supplied with the repair kit (see illustration).

10.6 Components of Bendix front caliper
10.6 Components of Bendix front caliper

1 Guide bolt
2 Caliper body
3 Pad retaining plate kit 4 Bleed screw
5 Mounting plate
6 Guide pin assembly
7 Repair kit

Refitting
7 Screw the caliper fully onto the flexible hose union, then position the caliper over the brake disc.

8 Clean the threads of the caliper mounting bolts, and apply a suitable locking compound to them. Refit the bolts along with the mounting plate, ensuring that the plate is fitted so that its bend curves away from the caliper body. With the plate correctly positioned, tighten the caliper bolts to the specified torque.

9 Securely tighten the brake hose union nut, then refit the brake pads as described in Section 4.

10 Remove the brake hose clamp or polythene, as applicable, and bleed the hydraulic system as described in Section 2.

Note that, providing the precautions described were taken to minimise brake fluid loss, it should only be necessary to bleed the relevant front brake.

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

Girling caliper
Removal
Note: New guide pin bolts must be used on refitting.

12 Proceed as described in paragraphs 1 to 4.

13 Where applicable, remove 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 (see illustration).

10.13 Removing a Girling caliper upper guide pin bolt
10.13 Removing a Girling caliper upper guide pin bolt

Discard the guide
pin bolt - a new bolt must be used on refitting.

Lift the caliper away from the disc, and unscrew it from the end of the fluid hose. Plug the open ends of the caliper and hose to prevent dirt ingress and fluid loss.

Overhaul
14 Proceed as described in paragraph 6 (see illustration).

10.14 Components of Girling front caliper
10.14 Components of Girling front caliper

1 Mounting bracket bolt 2 Bleed screw
3 Caliper body
4 Mounting bracket
5 Guide pin assembly
6 Repair kit

Refitting
15 Screw the caliper body fully onto the flexible hose union.

16 If the threads of the new guide pin bolts are not already pre-coated with locking compound, apply a suitable locking compound to them.

17 Manoeuvre the caliper into position, and fit the new upper guide pin bolt. Tighten the guide pin bolt to the specified torque, while retaining the guide pin with an open-ended spanner. Where applicable, refit the dust cover to the guide pin bolt.

18 Proceed as described in paragraphs 9 to 11.


© 2018 www.peugeot405.ru. All Rights Reserved.