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Projects and Restorations Building a car from scratch, restoring your pride and joy, building a track car, or starting a long term project? This is your place to document it.

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Old 16-02-2016, 11:23 AM   #11
robtech
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great stuff and good to see something rare and a bit different.
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Old 16-02-2016, 01:18 PM   #12
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I'm in for updates on this - looks like an excellent project and I think it's a superb idea to do it up on the memory of family.
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Old 16-02-2016, 01:25 PM   #13
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Really like the 405's. Went years with my parents to Spain on vacation. Never let us down. Same the 405 m16 almost never to find.

What engine is the SRI? 1800i ?
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Old 16-02-2016, 07:17 PM   #14
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Cheers for the comments guys.

The Sri is a 1900cc 8v engine. Essentially a 205 gti engine with a different head. XU9J2 is the engine type. Shared with the Citroen bx gti.
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Old 16-02-2016, 07:24 PM   #15
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My dad in law had a 405 GR with the 1.9 engine, although from what I remember it wasn't fuel injected.

Great work so far chum.

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Old 16-02-2016, 07:31 PM   #16
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More to come shortly when I get a chance.....
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Old 16-02-2016, 08:53 PM   #17
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I had an mi16 in cherry red - loved it - keep up the good work
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Old 16-02-2016, 09:38 PM   #18
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Posted 03 May 2008 - 10:12 PM

I had a semi productive day today. Spend a fair bit of it looking for those callipers I have lost. No luck there unfortunately. Its annoying as the brakes are the only thing stopping me moving the thing. Sods law dictates that I will get some from a scrappy and then I shall find my ones. Grr

Anyway, disappointed by my own memory (seeing how I have put these callipers somewhere and forgot) I decided to do something productive and prepare the car for the sunroof replacement.

Removal of the sunroof requires removal of the headlining so I started here. Pretty easy to do actually.

Started by removing the front pillar covers. These more or less just pull off.



Front pillar cover removed.

Next I removed the rear pillar covers. Again just pull them off.



Rear pillar cover removed

Next I removed the centre pillar covers. These are a bit more tricky. First you need to undo the holding screws at the top and bottom and then pull off the knob for moving the seatbelt height. This takes a good hard tug but will come off. Then remove the seatbelt and pull the cover off.

There are couple of wee bits to do now, front and rear compartment lights, jacket hooks etc.

Then the headlining should just pull down. Mine was held up by Velcro but yours may have glue so watch for this.

On inspection the headlining has some light damage. The fabric is hanging down a bit and the foam material it is made from is perishing in places it appears. Will need to repair this lot before I put it back together.



The headlining



Saggy bits.



More Saggy Bits

Once this is removed you can get access to the sunroof assembly. I did not remove this as it will leave me with a big hole in the sunroof. This can be done another day when I have the new sunroof.

Spent the rest of the day faffing with my 406. ABS is not working. The garage said its a faulty wiring loom and wanted £760 to replace it !! I will fix it myself I think. Found a faulty connector today. Will need to pay a visit to a scrappy to get the bits I need.

Hope I get good weather tomorrow.

Last edited by gingerscotsman; 23-07-2017 at 08:53 PM. Reason: Photobucket removal
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Old 16-02-2016, 10:13 PM   #19
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Posted 05 May 2008 - 11:06 PM

Some calliper refurbishment pics

First of all I took my very rusty calliper that I got from the scrap car at the weekend to work where I sandblasted it. I was left with the following.


Not so rusty calliper

Notice that I paid particular attention to the bleed nipple and main hose. If you can clean as much rust and dirt from the threads before you start it makes it alot easier and you are less likely to break anything.


Clean threads on nipples

These were loosened using a brake pipe spanner and a socket. As expected it was very easy as the threads were clean. If you cannot clean these up then I suggest alot of heat before attempting to remove the nipples. Otherwise you will round or snap them. This has worked for me on all the other callipers and I have 'yet' to break a bleed nipple


Tools required

Next step is to get the piston out of the calliper. I find an old foot pump works well here. Push the end of the hose into the pump and pump like mad. The piston should pop out.


My old foot pump.


Pop !!

This leaves you with the following.


Calliper and piston

Inspect the piston for signs of rust and damage. This one was nice and clean but will require a little dressing on the seal groove especially.

Piston before cleaning.

Following this remove the dust seal and inspect the calliper bore. In this calliper the seal was stuck in with rust and took a bit of getting out. The seal itself was intact but the rust over time can tear the seal and damage the bore.


Dust seal removed


The old dust seal.

It is important that all the rust in the seal groove is cleaned away before fitting a new seal. The calliper bore should be spotless. The piston seal in the bore should also be removed and replaced.


Dust seal and piston seal.

This lot all comes in a nice calliper overhaul kit from Peugeot. You get both seals. I have a bit of cleaning and painting to do before this lot is ready to go back together. Watch this space!!

Still need a rear passenger calliper if anyone has one kicking around???

Last edited by gingerscotsman; 23-07-2017 at 09:10 PM. Reason: Photobucket removal
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Old 16-02-2016, 10:18 PM   #20
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Posted 07 May 2008 - 06:09 PM

The caliper sliders come apart very easily. The following pictures are from the rear slider but you get the idea.


The slider before disassembly


Pull on this bit


This is what you end up with

Notice the above picture the grease is clean, moist and there is no signs of corrosion. Look at the other side.


The dark side

This side the grease is pretty dry and there are signs of corrosion. This was not seized but was on its way there. You get new grease, rods and rubbers with the overhaul kit so I will replace this lot as a mater of course.

Prepped my calliper for painting last night too.


Prepped for painting.

I have a couple of coats of Hammerite on now and will continue with more tonight. Cause its so hot in my flat today its not drying very well though

Posted 10 May 2008 - 10:25 PM

Had a reasonable weather day so I was quite busy.

Got my rusty rear calliper and took it to work along with my failed attempt at painting my wiper arms. I blasted these back to bare metal and the calliper looked great!


Blasted calliper


Blasted wiper arms

Set about checking out the calliper. I had unfortunately managed to get some blasting grit under the seals so I had to strip it. I have the overhaul kit so I am well to use it.

Stripping a rear calliper is a wee bit different to a front. It has a threaded rod inside (which is why you have to rotate it when pushing it back in if you have ever done your rear pads). So removing the piston is a case of putting the wind back tool on and winding the opposite way. The piston will just pop out. Then remove the dust seal and the piston seal for replacement.


Rear calliper in bits


Closeup on the threaded rod.

Got this lot masked up and painted.


Painted bits

Meanwhile I put my front brakes back together. Note I still have a rusty old brake disk and pads. I intend on changing these but I want the brakes working for now so I can move the car onto the driveway. The eagle eyed among you may have noticed the car is on the front lawn so my brother can use the driveway. His MG ZR does not go up it so it sits empty so the 405 is going back over.


Brakes back on.

Still got to make up the new brake pipe. My pipe flaring tool is slightly bent and is making poor ends. Will see if I can get another die tomorrow.

Aim for tomorrow (assuming the weather holds out) is to get the brakes working and the car back on the drive. If I get that far I may give it a wee wash and get rid of some of the green moss growing on it.

Last edited by gingerscotsman; 23-07-2017 at 09:14 PM. Reason: Photobucket removal
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