Peugeot 405 Manual

Handbrake cables - removal and refitting
Braking system / Handbrake cables - removal and refitting


Primary cable
Removal
1 Jack up the vehicle and support on axle stands (see Jacking and Vehicle Support).

2 Where applicable, remove the rear body undershield.

3 To gain access to the cable on certain models, it may be necessary to remove the heat shields from under the fuel tank and the rear underbody. To gain access to remove the heat shields, it may be necessary to remove the clamp securing the exhaust rear section to the intermediate section - this will allow the exhaust sections to move sufficiently to manipulate the heat shields out from under the vehicle.

4 Release the handbrake, then slacken the locknut on the adjuster mechanism and back off the adjuster nut (see illustration).

19.4 Handbrake lever and cable components
19.4 Handbrake lever and cable components

1 Handbrake lever
2 Switch assembly
3 Primary cable
4 Secondary cables

5 Release the primary cable from the clips on the underbody, then release the cable from the right-hand secondary cable at the connector, and from the adjuster bracket.

6 Working under the handbrake lever, detach the cable sheath from the lever mounting plate.

7 On models with a lowline centre console, pull the handbrake lever up, then unclip the front edge of the handbrake aperture trim panel from the top of the centre console.

Withdraw the trim panel over the handbrake lever.

8 On models with a highline centre console, remove the centre console as described in Chapter 11.

9 Pull the handbrake lever up to the 5th notch of travel, for access to the end of the cable.

10 Pull the end of the cable forwards and down to release it from the lug on the lever.

11 Feed the cable down through the lever mounting plate, and withdraw it from under the vehicle.

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

a) Ensure that the cable is routed correctly, and is free from kinks.

b) On completion, check and if necessary adjust the handbrake mechanism as described in Section 17.

Secondary cable -
models with rear drum brakes Removal
13 Proceed as described in paragraphs 1 and 2.

14 Slacken the locknut on the adjuster mechanism and back off the adjuster nut.

15 If the left-hand cable is being removed, remove the adjuster nut from the end of the threaded adjuster rod, then detach the end of the cable from the adjuster bracket.

16 If the right-hand cable is being removed, disconnect the secondary cable from the primary cable at the connector.

17 Remove the relevant brake drum as described in Section 9.

18 Using a pair of pliers, unhook the end of the handbrake cable from the operating lever on the trailing brake shoe.

19 Where applicable, tap the cable sheath end fitting from the aperture in the brake backplate, and feed the cable through the backplate (it may be necessary to remove the brake shoes for access - see Section 6) (see illustration).

19.19 Tapping the handbrake cable sheath end fitting from the brake backplate
19.19 Tapping the handbrake cable sheath end fitting from the brake backplate

20 Release the cable from the underbody clips, noting its routing, and withdraw the cable from under the vehicle.

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

a) Ensure that the cable is routed correctly, and is free from kinks.

b) Refit the brake drum (see Section 9).

c) On completion, check and if necessary adjust the handbrake mechanism as described in Section 17.

Secondary cable -
models with rear disc brakes Removal
22 Proceed as described in paragraphs 1 and 2.

23 Slacken the locknut on the adjuster mechanism and back off the adjuster nut.

24 If the left-hand cable is being removed, remove the adjuster nut from the end of the threaded adjuster rod, then detach the end of the cable from the adjuster bracket.

25 If the right-hand cable is being removed, disconnect the secondary cable from the primary cable at the connector.

26 Disconnect the end of the cable from the operating lever on the caliper, then release the cable sheath from the caliper bracket.

27 Release the cable from the underbody clips, noting its routing, and withdraw the cable from under the vehicle.

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

a) Ensure that the cable is routed correctly, and is free from kinks.

b) On completion, check and if necessary adjust the handbrake mechanism as described in Section 17.


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