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Old 16-02-2016, 10:29 PM   #21
gingerscotsman
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Posted 11 May 2008 - 09:48 PM

Had a productive day today. Mostly good points but a couple of extra issues to sort out.

Started off by finishing rebuilding the rear brakes.


Calliper back in one piece


And back on the car

Next I put on my nice shiny painted window wiper arms. What a difference they made.


Shiny window wiper arms

I then proceeded to bleed the brakes. I purchased I Gunson one man bleeding kit. Never seen one like this before. Basically uses pressure from a tire to pressurise the brake system at the cap to enable you to go round each wheel and just open the bleed nipple. Worked well on the front brakes but did not do a thing at the rear. I suspect my compensator valve is closed at the rear. I need a spring for it but they only sell the whole thing. It costs around £70

Whilst poking around at the front brakes I noted that I have managed to catch a bottom ball joint whilst fitting. Bugger. That will have to be replaced for the MOT. Noticed as well that I had not tightened the other side. Found out why. It appears that that balljoint is the wrong size. That will be 2 new balljoints then please. I hope I get them undone on the car. Don't want to have to take the hubs off again.

Anyway the front brakes working enabled me to move the car back onto the driveway. This will make jacking alot easier in future. The brakes did not have any feel at all though. Suspect its cause of all the air in the system at the rear. Need to sort that out.

The car run reasonably well although it does sound a wee bit off at idle and all the stop lights flash. The dash does not read the water temp either. As well as this the thermostat housing bleed screw needs replaced. Job for another day. Here is a wee video of it running.


Next I decided to give the thing a wee wash and make it look like a car again rather than a greenhouse. Some before and afters.


Green bits


Nice clean car


The side is clean too !!

This was a very rough wash. Will clay it and give it a right good going over once its a bit more together.

What to do next ....

Posted 12 May 2008 - 08:27 PM

Had a mess about tonight trying to bleed the rear brakes after reading some tips I found earlier using the search. Got a wee bit fluid through to the back but not enough to do anything. Will have to get the new compensator I think.

Whilst I was under there I was shocked by the amount of rust at the back. That will need some serious work to sort out. Considering dropping the rear axle to improve access to do a good job of it. Will give me the opportunity to get that painted too.

Took it for a little spin 50 yards up the road and back. Brakes worked (the front ones anyway) but the engine definitely is not right. That will be a bugger to fault find I think.

Last edited by gingerscotsman; 23-07-2017 at 09:19 PM. Reason: Photobucket removal
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Old 17-02-2016, 06:40 AM   #22
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Great write up and car have great memories of these cars. Keep up the good work!
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Old 17-02-2016, 05:23 PM   #23
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keep it up, these are nice looking cars, shame they are no longer about in any numbers, saying that I don't think i've even seen a 406 for a while.
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Old 17-02-2016, 09:26 PM   #24
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Posted 14 May 2008 - 12:30 PM

Ordered the compensator and ball joints from GSF yesterday afternoon and they arrived this morning!! I am very impressed with their service. The prices are not bad too (although the compensator was £75).

See about trying to fit some of this later today if the weather is ok. Looking pretty miserable at the moment

Posted 14 May 2008 - 08:50 PM
Had a look at my bits that arrived. Dead pleased with the new compensator. No pics today but will post tomorrow hopefully.

Had a go at replacing the damaged ball joint. It went very smoothly. That Dewalt impact wrench I bought is the best tool I have ever bought. Anyone that has ever tried to remove a ball joint when its on the car will testify to how difficult it can be. With the impact wrench it just popped off no problem. Probably helped that it was new though. I am liking working on the car more and more now that there are more new bits.

Whilst under the front had a look at the underside. Brake pipes front to rear look a little worse for wear as does the fuel pipes (which have also been patched in the middle with a bit of rubber hose I notice). They will all need replaced. Also had a look at how difficult it would be to drop the front subframe for refurbishment. Looks like it will be possibly more hassle than its worth as I will need to support the car on the sills with axle stands. Would be much easier if I had an inspection pit or ramps. So I think I may not do this and leave it for another day. Although I may change my mind.

If I get more good weather tomorrow night I think I will remove the rusted brake lines up to the old compensator so I can get that off for replacement. I see it sits on a bracket that could probably do with tarting up before going back on the car.

Till tomorrow

Posted 15 May 2008 - 08:59 PM
Did not have such a productive evening tonight. Wanted to turn the car around so it was facing the house to make working on the back end a bit easier. Unfortunately the engine would barely run for some odd reason. Started fine and ran fine for a few mins whilst I pumped up the flat tire. Then all of a sudden it started to run really rough to now where it barely starts.

I am wondering if it has perhaps run out of fuel and is running on the dregs in the tank. Will take off a fuel hose tomorrow and see.

Put some back to black on the trim outside. What a difference that has made to the look of the car. Looks almost as if it could drive again if it wasn't for the badly cracked tires. Intend on getting them replaced when the alloys get refurbished.

Posted 16 May 2008 - 09:42 PM
Time for today's update.

First the pictures of the new load compensator I promised.


Shiny new load compensator


Another view

Today I decided that the rear beam had to come off to inspect, help me get at the rust on the back end and get everything painted up. It will also make the compensator replacement easier.

So I proceeded. Here is a before pic for reference.


Rear beam on the car.

I jacked up the car and supported it using axle stands on the rear jacking points. Seems to be secure like that. The first sign of potential problems is the drivers side rear wheel. Does this look like a funny angle to you guys??


Funny angle or not??

The first thing in the way was the old spare wheel. Wheel carrier was seized (it was probably seized before it went odd the road. Crap design. This was removed.


Wheel carrier in the way.


And removed.

The actual carrier itself was seized at the hinges. I decided to take that off too. Got out my trusty can of WD40 and my impact wrench and set on to it. The first bolt came off fine but the other snapped. I sensed this was not going to go my way. Removed the carrier and then the rear silencer to give me a better look underneath. Not a pretty sight!!


Rusty bits


More rustybits.


Even more rust

Realise at this point that I had stupidly sat on my camera and cracked the screen!! Bugger. Its my own fault though. Will have to see if I can get a screen of the internet to replace it.

After this I scrapped away some of the worst of the rust and it maybe is not quite as bad as it looks. I hope! I disconnected the handbrake cables and tried to remove the compensator brake pipes. Of course they were seized too. One is rounded the other came off but is twisted. I intended on replacing these anyway.

But this is as far as I got. You need a long reach torx bit to remove the axle holding on bolts and by long reach ones are too to get through the hole in the axle. I will need to see what halfords sell tomorrow.

I hope I don't regret taking this off !!

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Old 17-02-2016, 09:31 PM   #25
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Posted 17 May 2008 - 11:42 PM
Today was not as productive as I would have hoped. I was hampered by rain for most of the morning and early afternoon. I got lots of underseal, seam sealer, krust etc from Halfords with the intention of getting the beam off and wire brushing.

Sadly I was stopped in my tracks when I could get all but one holding bolt out. The last one is the front one on the passenger side. Its rounded. Its another poor design by pug. Why do they insist on using Torx bolts everywhere. On the bottom of the car they are the first things to go rusty!!! Grr.

So beaten by this I gave up and set about scrapping the worst of the rust off the underside. Good news is that although it looks bad it mostly just loose surface rust. Had the car been on the road most of it would have fallen off by now. Still it comes off easily.

So tomorrow its more scrapping and hopefully get the drill with the wire brush attachment out.

I might also take my dremel with the cutting tool to that last bolt and see how I get on.

No pics today as I left the camera in the car. Doh!!

Posted 18 May 2008 - 11:38 PM
I had an excellent days work today

Had a bit of a brainwave last night as to how to get the last axle holding on bolt off. If you remove the rear seat you can access the top of the bolts. I proceeded to hammer on a female torx socket and off the bolt came. Very pleased indeed. Some pics from today and yesterday.


Removing an axle rear bolt.


Tools used to remove front ones.


Axle off the car

If anyone is doing this I would suggest in investing in some nice long torx keys from Clarke. Got them as part of a set from Machine Mart. They made this job alot easier.

With the axle off it was time to survey the condition at the rear and of the axle.


Axle off


Rusty underneath


Some nasty looking rust

Set about it with a wire brush attached to a drill


Cleaning in progress

This revealed that most of it is just surface rust with a few bits that were abit worse but salvageable. No obvious welding required. I can't weld so its just as well. If any of you are considering doing similar to your cars, I remind you that adequate protective equipment is a MUST.


Me looking like an idiot !!

Stripped the brakes etc of the axle again. Got all the brackets etc off it so I can clean and paint them. Managed to snap a couple of bolts in the process. Will have to get these out at a later date.


Bare axle

I think my plan next it to figure out how to strip the axle for inspection. Anyone ever done this?? Its not like to 205 one unfortunately. Also got more prep to do on the rear end before I can seal the seams, prime and underseal. May also need to drop the fuel tank. The holding bolts for it are badly corroded.

Progress may slow down a little now as I am probably going to be away for the next 2 weekends.

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Old 17-02-2016, 09:35 PM   #26
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Posted 22 May 2008 - 08:53 PM
Got a chance to be a wee bit more poking about today. I have been pulling back the underseal where it is obviously split and exposing alot of hidden rust (mostly surface rust). The drivers side rear sill was a big problem today though. Exposed a fair bit of what looked like surface rust then my finger went right through it. Poking about a bit more revealed a massive hole in the sill that was just held together by the underseal. No pics today but I will try and get some tomorrow.

It looks like its an easy welding job to fix but still another thing I was not counting on. Will have to get my pal to weld it for me.

I need to learn to just ignore some bits I think. I was very close to removing the rear bumper tonight cause I saw some rust under there.

Posted 25 May 2008 - 09:32 PM
Been at the Jim Clarke rally all weekend so not much progress to report.

Did stop off on the way home though. Got some painting done on the nicely cleaned underside. Bit short on pics from the cleaning process but there is one pic above. It was very messy indeed.

During the cleaning I decided to peel back the underseal where there were obvious cracks or bulges. These were cleaned up with my wire brush drill and painted with a zinc based spray primer. Used this primer on all the other cleaned parts on the underside.

Today moved onto a thicker anti rust primer applied using a brush. The whole rear underside took 2 1/2 hrs ! Worth it though, its amazing the difference it makes.


Parts were underseal was peeled back.


Drivers side sill rear. Notice the hole at the bottom. There is more where that came from!


Underside painted in primer


More primer pics


The hole

I would quite like to remove the fuel filter and the other thing (fuel pump?) and get behind them but the bracket is so rusted that I don't think I would be able to get it off without damaging it. Just paint it and hopefully it will last a few years yet.

After a wee bit humming and hawing I have decided to have a go at rebuilding the axle. Its off and it would be a shame to put it back on only to realise that it has to come off again. This way I know its good and I can have it cleaned and painted whilst I am at it.

Wish me luck.

Tomorrow I am away to visit a decommissioned power station at Inverkip before they knock it down. Weather dependant though I hope to get stripping that axle this week and get another coat of primer on.

Posted 29 May 2008 - 10:33 PM
Time for today's update. Today I put a second coat of primer on the underside. Not got any pics of that but it looks the same as above

Once I was finished doing that I had a go at the axle. First job I had was to remove the rear hubs. These needed to come off anyway as they are non ABS items (from when the axle was replaced before) and I want to get the ABS working again for the MOT. They were pretty easy to remove. Pull off the dust cap then remove the hub nut. Put a set of pullers over the hub and tighten up and off the hub comes. Leaves the inner race on the stub axle but I will cut this off another time. I also took the opportunity to remove the mounting bracket and the brake shield (although the shield requires the inner race off so that will have to wait).


Hub nut that does not know what is about to happen


Hub off


Stub Axle closeup.

Next I had a go at removing the mounting bushes.


Bush on the axle

Firstly you have to slacken the centre mounting bolt and tap it out with a hammer.


Removing a bush

This leaves you with the bush on its own. On inspection mine appear absolutely fine. No issues with them at all. I may just leave them in. What do you guys think? Should I go to the hassle of fitting powerflex or similar items if available? Is it actually worth it?


Bush on its own

Next I had a go at removing the struts. These are weeping and will need replaced. Managed to get the top bolt out but the bottom one is held by a rather large Allen key bolt. Its about 14mm. Who has an Allen key that size??? Trip to halfords for me I think next opportunity.

So I am now at the point where I have to decide do I strip the axle further or not. I have read somewhere that I need a dummy shock? Does anyone know if this is the case? The haynes manual is reasonable but does not go into the detail I need to get this right. Don't want to bugger up the ride height or worse.

Anyone ever done this who can do me a quick how too?

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Old 17-02-2016, 10:43 PM   #27
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Really enjoying this thread! great work from yourself Mate for getting stuck in and giving it ago! I wouldn't have a clue! Haha.

I look forward to seeing the next lot of previous updates and how the car is now
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Old 18-02-2016, 01:57 PM   #28
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This is great, love seeing a car being fixed up that is special to you. Great work all the best with it.
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Old 18-02-2016, 07:10 PM   #29
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Quote:
Originally Posted by gingerscotsman View Post

So I am now at the point where I have to decide do I strip the axle further or not. I have read somewhere that I need a dummy shock? Does anyone know if this is the case? The haynes manual is reasonable but does not go into the detail I need to get this right. Don't want to bugger up the ride height or worse.

Anyone ever done this who can do me a quick how too?
Quick guide on how to lower a 205 axle, which is basically the same, the overhaul requires a little more work as you'll need to get new bushes etc for the axle tube and hope the spindles are okay on the trailing arms

Peugeot Lowering


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Old 18-02-2016, 09:43 PM   #30
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Posted 16 June 2008 - 12:06 AM
I have been a bit quiet recently but have got some work done in the mean time.
Last weekend I managed to get the underside seam sealed. Not managed to get any pics off the camera for that though. Did not have my own camera but I will try and fill them in later on.

Also had a go at stripping the rear axle. Managed to get the anti roll bar off pretty easily. Failed at the next hurdle though. Could not get the trailing arms off. Gave up in the end. What it did prove to me was that the trailing arms still move and there is no play that I can feel in the bearings. Will clean the axle up and paint it. Again no pics here.

Was rained off yesterday but today I had a fairly productive day. Got the underside rear fully coated in underseal. Just painted it on nice and thick and I think it came out great. Here's some pics.


Underseal


More underseal.


Even more underseal.

I mentioned before that I had to replace the rear hubs for ABS units so I can get my ABS working again. I had pulled of the hubs a few weeks ago and set about removing the inner bearing race and cap today. Pretty easy job. The way I did it was to grind a small groove in the race with my dremel and then whack it with a chisel and hammer to get the bearing to crack. Then it just pulls off. The pics will show you what I mean.


Inner race on stub axle


Cut a groove in the race with a dremel.


Whack it with a hammer


Once the race is off prise off the dust cap.

This also allowed me to remove the brake shield so I can clean and paint it.


Rusty and dirty brake shield.

Hopefully I will get into cleaning up the axle this weeks so I can start painting it. If it ends up needing an axle at some point in the future I will end up paying for it to be done I think. Getting the trailing arms off looks like a nightmare!!

Posted 26 June 2008 - 08:53 PM

Got back down to the car again tonight. Have had a bit of a saga with my 406 that has prevented me getting near the 405 Still its all fixed now and I can get on again with the 405.

Checked out my undersealing job tonight and was very happy indeed with the results. Thats great stuff and dries fairly smooth. Put another coat on tonight for good measure. No pics I am afraid but it looks like those above only blacker !!

Was having a look at this beam again tonight. It does not look like it has any play in it the wrong way and looking again at the pic I posted earlier I remembered that the car was jacked up so will look abit strange. So I think this is where my skill and patience ends. The trailing arms seem free enough so I am going to put it back together, paint it and hope for the best.

So this weekend its beam cleaning and painting for me. I also have to order some fixing bolts etc from Pug. Hope the weather is good.

Posted 12 July 2008 - 09:09 PM
Time for a quick update.
I have been a little busy with other things recently so the 405 has not been getting as much attention as I would have liked. Still, I have managed to clean up the rear beam and am in the process of giving it a nice coat of paint before it goes back on.

I don't have any painted pics yet but here's how it looked after I cleaned all the grime and underseal off it.


Cleaned beam


Closeup


Another closeup

I have stuck with the original colours so I have painted the centre tube yellow, arms black and torsion bars red with the anti roll bar black. I have even been sad and painted yellow stripes on the torsion bars

Will take some pics next time I am down.

Plan after that is to start rebuilding the beam components, brakes, compensator valve etc. in preparation for getting it back on the car.

Oh and I also need to get a easy out that I got stuck in a knackered bolt out. Probably the hardest thing I have to do.

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