Peugeot 205 Manual

Front brake pads - renewal
Braking system / Front brake pads - renewal


Warning: Disc brake pads must be renewed on both front wheels at the same time - never renew the pads on only one wheel as uneven braking may result. Dust created by wear of the pads may contain asbestos, which is a health hazard. Never blow it out with compressed air and do not inhale any of it. DO NOT use petroleumbased solvents to clean brake parts. Use brake cleaner or methylated spirit only. DO NOT allow any brake fluid, oil or grease to contact the brake pads or disc. Also refer to the warning at the start of Section 2 concerning the dangers of hydraulic fluid.

All models except 1.9 GTI 1 Chock the rear wheels then jack up the front of the car and support it on axle stands (see Jacking and vehicle support). Remove the front roadwheels.

2 Note that two different types of brake caliper may be fitted according to model and year. Identify the type fitted, with reference to the accompanying illustrations or the caliper itself, then proceed as described under the relevant sub-heading.

DBA Bendix caliper
3 Remove the clip from the end of the upper sliding key. Disconnect the pad wear wiring connector as necessary (see illustrations).

4.3a Pad sliding key clip - arrowed (DBA Bendix caliper)
4.3a Pad sliding key clip - arrowed (DBA Bendix caliper)

4.3b Disconnecting the pad wear wiring connector (DBA Bendix caliper)
4.3b Disconnecting the pad wear wiring connector (DBA Bendix caliper)

4 Pull out the upper sliding key (see illustration).

4.4 Removing the pad sliding key (DBA Bendix caliper)
4.4 Removing the pad sliding key (DBA Bendix caliper)

5 Using a lever against the front suspension strut, push the cylinder towards the brake disc so that the outer pad can be withdrawn from the caliper (see illustration).

4.5 Removing the outer pad (DBA Bendix caliper)
4.5 Removing the outer pad (DBA Bendix caliper)

6 Push back the caliper and withdraw the inner pad (see illustration). Make a note of the correct fitted position of the anti-rattle springs and remove the spring from each pad.

4.6 Removing the inner pad (DBA Bendix caliper)
4.6 Removing the inner pad (DBA Bendix caliper)

7 Clean away all dust and dirt from the caliper. Check for brake fluid leakage around the piston dust seal and, if evident, overhaul the caliper, as described later in this Chapter.

Check the brake disc for wear and also check that the rubber bellows on the cylinder sliding rods are in good condition.

8 Clean the backs of the brake pads and apply a little anti-squeal brake grease. Also apply the grease to the lower pad locating lip of the caliper.

9 With the caliper pushed inwards, insert the inner pad then push the caliper outwards and insert the outer pad. If offset pads are fitted, it is important to fit these pads in the correct positions as shown (see illustration). The inner pads with pad wear wires must be located at the top of the caliper.

4.9 Correct orientation of offset brake pads viewed from front of vehicle
4.9 Correct orientation of offset brake pads viewed from front of vehicle (DBA Bendix caliper)

10 Check that the pads are correctly positioned on the caliper lip and with the antirattle springs in place (see illustration) then tap in the upper sliding key to lock them. Fit the sliding key clip.

4.10 Fitted position of the anti-rattle springs on the brake pads (DBA Bendix
4.10 Fitted position of the anti-rattle springs on the brake pads (DBA Bendix caliper)

Girling caliper
11 Extract the spring clips and tap out the pad retaining pins. Disconnect the pad wear wiring as necessary (see illustration).

4.11 Girling brake caliper and pad arrangement
4.11 Girling brake caliper and pad arrangement

12 Lever the cylinder outwards and withdraw the outer pad then push in the caliper and withdraw the inner pad. Recover the antisqueal shims (if fitted) noting their positioning with regards to the pad retaining pins - refer to paragraph 14.

13 Clean and check the caliper, as described in paragraph 7, then clean the backs of the pads and apply a little anti-squeal brake grease. Note that, as from early 1985, a special spring is fitted to the inner pads to prevent pad knock within the caliper. The spring (obtainable from Peugeot dealers) may be fitted to earlier models by tapping the inner pad control rivet through the backing plate so that the clip may be located on both sides (see illustration).

4.13 Method of fitting anti-knock spring to Girling inner brake pad
4.13 Method of fitting anti-knock spring to Girling inner brake pad

1 Loop for rivet
2 Loop for lower retaining pin 3 Anti-knock spring

14 With the caliper pushed inwards, insert the inner pad then push the caliper outwards and insert the outer pad. Note that from chassis no 5 600 000, an anti-squeal shim was fitted between the inner pads and the caliper pistons, being located on both upper and lower pad retaining pins. However, as from chassis no 5 957 000, the shim was modified, being located only on the lower pad retaining pin (see illustrations).

4.14a Early type anti-squeal shim (Girling caliper)
4.14a Early type anti-squeal shim (Girling caliper)

4.14b Later type anti-squeal shim (Girling caliper)
4.14b Later type anti-squeal shim (Girling caliper)

When fitting the anti-squeal shims, the arrow cut-out must face downwards (ie in the forward rotational direction of the disc).

15 Tap in the pad retaining pins and fit the spring clips.

16 Where fitted, hook the anti-knock spring on the lower pad retaining pin.

1.9 GTI models
17 Chock the rear wheels then jack up the front of the car and support it on axle stands (see Jacking and vehicle support). Remove the front roadwheels.

18 Disconnect the wire for the pad wear warning light.

19 Hold the lower guide stationary with one spanner, then unscrew the bolt (see illustration).

4.19 Unscrewing the lower caliper guide pin bolt (1.9 GTI)
4.19 Unscrewing the lower caliper guide pin bolt (1.9 GTI)

20 Swivel the caliper upwards, then withdraw the two brake pads from the caliper bracket (see illustrations).

4.20a Swivel the caliper upwards . . .
4.20a Swivel the caliper upwards . . .

4.20b . . . then withdraw the two brake pads (1.9 GTI)
4.20b . . . then withdraw the two brake pads (1.9 GTI)

21 Clean and check the caliper, as described in paragraph 7.

22 Push the piston fully into the cylinder.

23 Clean the backs of the pads, and apply a little anti-squeal brake grease. Refit the inner pad (with the pad wear warning wire), then the outer pad.

24 Lower the caliper. Apply locking fluid to the lower guide bolt, insert it, and tighten to the specified torque while holding the guide stationary with another spanner.

25 Reconnect the pad wear warning light wire.

All calipers
26 Repeat the operations on the opposite disc caliper.

27 Apply the footbrake several times to position the pads against the discs.

28 Top-up the master cylinder reservoir to its correct level.

29 Refit the roadwheels and lower the car to the ground.

30 Note that if genuine Peugeot replacements have been fitted, these pads have a thin coating of abrasive material, which cleans the disc during the initial applications of the brakes. This coating also removes any disc imperfections which would cause steering vibration. After fitting these pads, the brakes must be applied lightly and intermittently for the first 3 miles (5 km), then bedded-in for 120 miles (200 km), avoiding heavy or prolonged braking wherever possible.


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