Peugeot 405 Manual

Master cylinder - removal, overhaul and refitting
Braking system / Master cylinder - removal, overhaul and refitting

1 Disconnect the battery negative lead.

2 Remove the cap from the brake fluid reservoir, place a piece of polythene sheet over the filler neck, and refit the cap tightly.

Alternatively, siphon all the fluid from the reservoir using an old teat pipette or poultry baster. This will minimise fluid loss during the following procedure.

3 To improve the clearance available for removal, remove the windscreen wiper arms (see Chapter 12), then remove the scuttle cover panel from the front edge of the windscreen (see Chapter 11).

4 Disconnect the wiring from the low brake fluid level warning sensor.

5 Unscrew the two nuts securing the master cylinder to the brake vacuum servo unit (see illustration).

13.5 Master cylinder securing nut (arrowed)
13.5 Master cylinder securing nut (arrowed)

6 Unscrew the union nuts, and disconnect the brake fluid pipes from the master cylinder.

7 Lift the master cylinder, complete with the fluid reservoir, from the servo unit (see illustration).

13.7 Removing the master cylinder from the vacuum servo
13.7 Removing the master cylinder from the vacuum servo

Hold a cloth under the assembly to catch any fluid spillage. Recover the sealing ring.

8 Unscrew the clamp nut and bolt, release the plastic clamp, and withdraw the fluid reservoir from the master cylinder.

9 No spare parts are available from Peugeot for the master cylinder, and if faulty the complete unit must be renewed.

10 Refitting is a reversal of removal, bearing in mind the following points.

a) Examine the master cylinder sealing ring and renew if necessary.

b) Ensure that the brake pipe union nuts are securely tightened.

c) Refit the windscreen wiper arms with reference to Chapter 12.

d) On completion, remove the polythene, where applicable, then top-up and bleed the hydraulic system as described in Section 2.

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