Peugeot 405 Manual

Anti-lock braking system (ABS) components - removal and refitting
Braking system / Anti-lock braking system (ABS) components - removal and refitting


Front wheel sensor
Removal
1 Disconnect the battery negative lead.

2 To improve access, apply the handbrake, then jack up the front of the vehicle and support securely on axle stands (see Jacking and Vehicle Support). If desired, remove the roadwheel.

3 Trace the wiring back from the sensor, then disconnect the sensor wiring connector (on most models, the sensor wiring is routed through the inner wing panel, and the connector is located in the engine compartment.

4 Release the sensor wiring from any securing clips and, where applicable, push the wiring grommet from the inner wing panel and feed the wiring through the panel.

5 Unscrew the securing bolt, and withdraw the sensor from the hub carrier (see illustration).

24.5 ABS front wheel sensor (arrowed)
24.5 ABS front wheel sensor (arrowed)

Refitting
6 Before refitting a sensor, ensure that the tip is clean. Where applicable, on new sensors remove the protective sticker from the tip.

7 Fit the sensor to the hub carrier.

8 Clean the sensor securing bolt, then apply thread-locking compound to the bolt threads.

Fit the bolt and tighten to the specified torque.

9 On models fitted with the Bendix integral ABS system, proceed as follows (see illustration).

24.9 ABS front wheel sensor adjustment (adjuster arrowed) - Bendix integral
24.9 ABS front wheel sensor adjustment (adjuster arrowed) - Bendix integral ABS

a) Loosen the sensor adjuster bolt.

b) Position a 0.5 mm feeler blade between the sensor tip and the sensor ring on the driveshaft.

c) Press the sensor lightly against the feeler blade, and tighten the adjuster bolt to the specified torque.

d) Remove the feeler blade.

10 On completion, where applicable refit the roadwheel and lower the vehicle to the ground.

Rear wheel sensor
Removal
11 Disconnect the battery negative lead.

12 To improve access, chock the front wheels, then jack up the rear of the vehicle and support securely on axle stands (see Jacking and Vehicle Support).

13 Trace the wiring back from the sensor, then disconnect the sensor wiring connector (on most models, the sensor wiring is routed through the floor of the vehicle, and the connector is located behind the luggage compartment side trim panel.

14 Release the wiring from the clips underneath the vehicle, and feed the wiring through the floor panel.

15 Unscrew the securing bolt, and remove the sensor from the trailing arm (see illustration).

24.15 Rear wheel ABS sensor (arrowed)
24.15 Rear wheel ABS sensor (arrowed)

Refitting
16 Before refitting a sensor, ensure that the tip is clean. Where applicable, on new sensors remove the protective sticker from the tip.

17 Lightly grease the sensor location in the trailing arm, then refit the sensor.

18 Clean the sensor securing bolt, then apply thread-locking compound to the bolt threads.

Fit the bolt and tighten to the specified torque.

Electronic control unit - Bendix ABS systems
Removal
19 Disconnect the battery negative lead.

20 The unit is located in the scuttle at the rear of the engine compartment (see illustration).

24.20 Electronic control unit location (arrowed) - Bendix integral ABS
24.20 Electronic control unit location (arrowed) - Bendix integral ABS (left-hand-drive models shown)

21 Open the bonnet, and unclip the cover from the top of the scuttle to expose the control unit.

22 Release the securing clip, and disconnect the wiring plug from the top of the control unit.

23 Unscrew the clamp bolts or nuts, as applicable, securing the unit to the housing, then carefully withdraw the unit. Note that on some models, it may be necessary to disconnect the control unit wiring harness earth lead before the unit can be withdrawn.

24 Where applicable, separate the control unit from the mounting bracket.

Refitting
25 Refitting is a reversal of removal, but where applicable ensure that the wiring harness earth lead is securely reconnected.

Electronic control unit - Bosch ABS system
Removal
26 Disconnect the battery negative lead, then unclip the control unit cover from the top of the modulator assembly.

27 Disconnect the three wiring connectors from the control unit, then slacken and remove the six Torx retaining screws, and lift the control unit away from the modulator assembly (see illustration).

24.27 Bosch ABS electronic control unit securing screws (arrowed)
24.27 Bosch ABS electronic control unit securing screws (arrowed)

Refitting
28 Refitting is a reversal of the removal procedure. Ensure that the wiring connectors are securely reconnected, and do not overtighten the retaining screws.

Hydraulic control unit
and modulator assembly - Bendix integral ABS
Note: Refer to the Warning in Section 23.

29 No attempt should be made to remove any of the hydraulic system components on models equipped with the Bendix integral ABS - refer the operation to a Peugeot dealer.

Modulator assembly -
Bendix additional ABS
Removal
30 Disconnect the battery negative lead.

31 Where applicable, unclip the plastic cover, then disconnect the wiring connectors from the modulator assembly.

32 Mark the locations of the hydraulic fluid pipes to ensure correct refitting, then unscrew the union nuts, and disconnect the pipes from the modulator assembly. Be prepared for fluid spillage, and plug the open ends of the pipes and the modulator, to prevent dirt ingress and further fluid loss. Note the position of the clip on the brake pipes to ensure correct refitting.

33 Working under the modulator, unscrew the two nuts securing the vertical mounting plate to the main bracket (see illustration).

24.33 Modulator assembly vertical mounting bracket-to-main bracket nuts
24.33 Modulator assembly vertical mounting bracket-to-main bracket nuts (arrowed) - Bendix additional ABS

Withdraw the plate and the mounting rubber assembly.

34 Unscrew the two nuts securing the remaining mounting studs to the main bracket, then manipulate the modulator assembly from the bracket.

Refitting
Warning: Do not reconnect the wiring connectors to the modulator until the hydraulic circuits have been bled as described in Section 2.

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

a) Before refitting, examine the mounting rubbers, and renew if necessary.

b) Reconnect the fluid pipes to the assembly, as noted before removal, ensuring that no dirt enters the system.

Ensure that the brake pipe clip is fitted as noted before removal.

c) Before reconnecting the wiring connectors, bleed the complete hydraulic system as described in Section 2.

Modulator assembly -
Bosch ABS
36 Refer to paragraphs 30 to 35 of this Section for the Bendix additional ABS.


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