STEERING Contents Section 7 Description Technical Data Removal... Disassembly ‘ Adjustment and Assembly Installation . .. Tie Rod Ball Joint Disassembly or 7 Reassenbly 1) Tools zw DESCRIPTION The Peugeot 404 is equipped with a which features an automatic play tak ‘and pinion type steering gear p device, The steering ratio of 18.6 to 1 provides a direct control of the wheels, without looseness, while giving an easy handling. The steering ge housing made of aluminum alloy is located behind the front cross- member. The steering column is connected to the pinion flexible rubber joint. The left tie rod is secured to the rack by a bell Joint providing, through fractions of a tum, a very accurate adjustment of the toe-in.TECHNICAL DATA = Number of teeth on rack 30 ‘Number of tasth on pinion 8 = Ratio 18.6 to1 = Turning circle 31 ft. 8 in. = Lock to lock steering whee! turns 33/4 ~ Toe-in Adjustment 1/16"" with 1/644" tole — Toesin Adjustment from ball joint T turn = 1/8" on wheels REMOVAL OF STEERING ASSEMBLY Disconnect the battery. | 2-Lift the oar on a rock withthe font wheeln sci chee 3 Disconnect the steering column from the flexible rubber joint by removing the lock bolt of the clamp. DISASSEMBLY 1-Remove the pin bolt from the right tle tod yoke 2 Remove the outer bellows clamps, I} 3 Loosen the sight fond counter ast and renove the 1ack eye 4+ Loosen the left hand ball joint ‘counter nut and remove the tie rod. STEERING 4. Disconnect both tie rode from the steering arms, using Puller 8,0703E. 5+ Remove the two bolts securing the steering gear housing to the cro member. 6» Remove steering gear assembly. 5 - Remove the bellows, 6 + Remove the pinion cover. 7+ Loosen and remove the pinion mut, 8. Remove both rack plungers. On the plunger located above the pinion, save the spacer and adjustment shims for further use, 9 « Remove the pinion.STEERING 10- Remove the rack, 11- Remove from the pinion = the flexible joint = the rubber stop the rubber ting 12 Remove the snap ring and the bear- Ing from the steering housing 13 Hold the rack in @ vise fitted with Toad jaws. 14- Loosen and remove the ball joint cover nut using socket 8.0703 B. 1S- Remove the ball joint, the adjust- ment shims, the cup shaped washer leville" washers. ADJUSTMENT AND ASSEMBLY 1-Hold the rack vertically in a vise fisted with lead jaws. 2-- Install adjusting clamp 8.0703 on the rack (1). 3+ Install @ new ball joint and torque to 30 ft. Ibs. 4 Seat the adjusting clamp against the ball Joint cover nut (2) and tighten the lock bolt, 5 + Remove the ball joint cover nut onl -—@ 7 YY WMA ~ Install eup shaped washer (4) in the ae Using rod 8.07030 to center the cup shaped washer, install the ball joint (6) and cover nist (2) =Remove the centering rod 8.0703D fand tighten the cover nut until the ball joint is hard to ewing, With « feeler gauge, measure the dis- tance (x) between the cover nut (2) and the adjusting clamp (c). + Add .002 to this measurement, to de- termine the thickness of the shim to be inserted between the rack and the cover nut. This will leave @ proper clearance of .002 after the ball joint is assembled. Adjusting Shime Thickness Part 004 3637.01 008 3837.04 +008 3637.02 010 3637.03+ Remove the cover nut, the ball joint, the cup washer and’ the adjusting clamp. + Tnstall 020" thick spacer in the bottom of the rack bell joint recess. From Belleville washer set (Part No. 3839.02) place shims (1) if any, over the spacer, then install 13 "Belleville" washers (2) positioned as shown, NOTE: Port 93839.02 is packaged with ‘rough shims, predetermined to exe oF the proper fore. De not 0dd or subtract shine. + Install the adjustment shim determined in Operation #10. + Install the cup shaped washer, the bell Joint together with the centering rod STEERING 16 Install @ new cover nut and torque to 30 ft, Ibs. using socket B. 7 = Install the becring and snaptsing into the steering housing. + Install the flexible rubber joint and the clamp on the pinion using new bolts, ‘Torque the bolts to 10 ft. lbs. and stake the threads. Install the rubber ring + Slide the rack into the housing letting the right side of the rack protrude fom the housing by 37/8", = Engage pinion 2a that clamp bolt hole is cligned parallel to the rack.STEERING Za ZA y sh Meath | paraiiel to the Fack 21+ Install @ new nut on the pinion, 2% - By means of the nylon spacer (4) rari eo anitkc eas cid otal? secure adjustment shims (2) deter- mined above, on the threaded portion 22 - Install pinion cover, of the grease nipple protruding from the flanize (3), 23 Install the right hand plunger and torque the flange bolts to 10 ft. Ibs. Install the plunger in the housing and torque the flange bolts to 10 ft be. 28- Operate the steering gear in both ns to check for any stiff points. 29 - Clamp the bellows onto the housing, Install the left tie ‘rod and its ounter nut (4) on the ball joint. A 30- distance of .945"" (15/16) should 24. Place the spacer of the left hand bo kept between the counter nut (4) plunger on a plane surface and set ‘and the cover mut (5), Do not torque the plunger (1) over the counter nut at this tie, 28+ Insert one or shims (2) be tween the spacer and the bottom of the plunger until a clearance of .080 .s obtained between the plunger and the plane surface. + ent Shims Aajus ThicknessSTEERING 31 Install the rack eye and its counter 3+ Connect the tie rods to the steering | mut on the rack, Keep a distance of arms. Torque the mute to 35 ft Ibe, } 3/8" 10 7/16" between the counter and lock with 2 cotter pins. aut (4) and the shoulder of the eye (6), Do not tighten the counter nut 4+ Align the yoke of the R.H, te rod at this tine with the eve of steering rack and tighten the counter nut. i 5 Tlahten yoke pin bolt and lock with | a cotter pin. | 6+ Adjust too-in to 1/16" with 1/64" tolerance by screwing of unscrewing the bol joint ofthe left hand te rod, | [A <= Tighten the counter nut a Rohe 7 = Comect the rubber bellows. 8 - By turning the steering wheel from +k to lock, check that the wheels core not touching the frame. 32. Install the right tie rod with the cone of the ball joint facing up. Do que the pin bolt. 9 - Grease steering assembly. 10 Road test the car in order to check the alignment of the steering wheel. The alignment can be corrected by INSTALLATION removing the steering wheel (using Puller A) and replacing it on the 1+ Secure the steering gear on cross- shaft in the proper position. member and torque the (wo bolts to 30 ft. Ib 2. Using a new bolt, connect the steer | ing column to the clamp of the flex- | Able rubber joint. Torque the bolt to Hi 7 ft. Ibs. Stake the bolt on the threads.STEERING TIE ROD BALL JOINT Disassembly fold the tie rod in a vise. 2+ Remove the snap ring (6) with the use of a drift pin through the small hole (q) in the side of the ball joint housing Catch the following: = ball joint cop (5) = four Belleville washers (4) = lower nylon half bearing (3) = ball joint (2) = upper steel half bearing (1) + Place the steel half bearing (1) in he bottom of the socket, 2. Install the following: = ball Joint (2) = nylen half beating (3) = our Belleville washers (4) sitioned az shown all joint cap (5) 3-Apply pressure on Belleville weshers ond install a new snap Hing (6). Position ball head se that the cotter pin hole makes « 90* angle with the le rod, 5- Grease ball joint housing. Tool Kit #8.0703 A — Puller - Steering wheel B ~ Socket - Ball joint C —Clomp - Ball joint adjustment D — Rod - Cup washer centering E — Puller - Tie rod ball joint NOTE: Tool Kit 6.0703 con be ordered from the ditributorBRAKES + Section 8 Master Cylinder... Sees re 82 Stop Light Switch vee sess cece ae on 82 Brake Fluid ...... ocr eines a2 Bleeding the Hydraulic System pebaet och a2 Brake Drum o one ees Rear Broke, 83 Front Brake : Ba Brake Shoes Adjustment Bes, Hand Brake Adjustment ...,,, 85 Notes on Maintenance ...,, BS DESCRIPTION ‘The braking system consists of « hydraulically operated clrcult which applies the brake shoes simultaneously at all four wheels, and a mechanically operated patk~ {ng brake that applies the brake shoes at the reat wheels. E 1 broke is equipped with two wheel cylinders of the single piston type, while each rear wheel brake is equipped with one wheel cylinder of the double piston type. To keep out dust and moisture and to prevent gumming of the brake fluid, each piston fend of a wheel cylinder is sealed with a rubber boot. front wh ‘The parking brake handle is located to the left side of the steering column. font Broke Reer Broke elMoster Cylinder The master cylinder is located in the engine compartment and secured on the fine wall, It ie fitted with @ glaze reset voir which allows a quick check of the hydraulic dud level without removing the filler cop. ‘The glass reservoir is fitted at the bottom by a metallic cop with left hond thread, This cap secures the reservoir onto the ‘mastercylinder body by means of a con- rector. When installing the reservoir onto he master cylinder, tighten only the con- ecter with @ socket. Do not tum the ato 8 Gasket Connector Washer BRAKES The clearance betwoen the push rod and ‘and the mastercylinder is .010" to 075", This clearaice 1s factory atjusted and should not be altered, When bleeding the brake system, refill reservoir to "maxi" level mat and check that the vent hole of filler cap is not clogged. Stop Light Switeh ‘The stop light switch is attached to the master cylinder. It is actuated by the pressure of the broke fluid when the pedal is depressed. Its calibration is 45 past. £15. ‘The hydraulic system is factory filled with "Lockheed HD31" or "Stop HD 36!" brake fluid which are compatible with ‘"iagner Lockheed 218" heavy duty (SAE 70R3 or 7OR1). Either may be added to the system, Bleed the Hydreulle System I the broke pedal feels spongy, or @ line hhos been disconnected, st 1s necessary to bleed the brake lines manually or by us- ing pressure bleeding equipment. [ts suggested thot bleeding be done on the longest line first. The manual bleeding procedure is as fol- lows: + Remove the filler cap of the master evlinder,BRAKES aa 2.- Remove the rubber cap from the bleed: A rum that is more than .004"' out-of er valve and install a hose onto the Sa bleeder valve, placing the other end of hhose in @ Jor containing sufliclent fluid to cover ite end ‘A drum should not be rebored more thon [040"" over the etandard size, 3 Open the bleeder valve at the whee! vlinder. 4+ Depress the broke pedal by hand, allowing it to retum slowly. Continue this pumping action until bubbles stop and fluid flows in a olid 8 5+ Close the bleeder valve, MOTE: In order 12 avoid misshoping of the wheal cylinder, the blecder Valve should be tightened ely (10% lbs). the 6-Renove the hose and replac rubber cap on the bleeder valve, 7 Repeat these operations at each Rear Broke wheel. ae ‘The rear brakes are of the floating type, equlpped with one wheel cylinder in each backing plate, ‘The length of the leading Lining ist 0.511", ‘The length of the trailing lining is: 8622". Note thot the longer lining ix installed of the fron. ‘The width of both linings is: 1.377", ‘The inside diameter of the dum is 10.039". The diameter of the kore of the wheel cylinder ie: 1”, ‘The front and rear brake drums are very rigid, and made of hard cast ison, They cre Secured onto the hubs by means of three bolts, Whenever broke drums are removed, they should be thorcughly checked for cracks, Seeee teen eee Since the drums ond shoes of @ rear broke fre smaller in width, they ore not infers changeable with the drum or shoes of © ight scores con be sncothadp with « ee ee front brake. very fine emeryFront Brak ‘The front brokes are equipped with two wheel cylinders on each backing plate, Since Serial #4108665, some modifica Parts are rot interchangeable between the ourly and Inte models. Complete as- senblies (backing plates, wheel oylin- ders, shoes and drums) may be replaced cn both wi tions have been peiformed on the front eae Only the ports Listed below are Inter changeable between early and late ‘model: 1- Oil Retainer 2 Shoe Retum Spring 3 - Shoe Hold Down Spring 4- Wael Cylinder Push Rod 5+ Connecting Pipe 6+ Bleeder Valve (fitted on the rear eyl+ inden) PARTS Up Sevtel 100664 From Serial 4108665 | ont Crise (a a ayer 9 av" 0mm) Rear Cylinder (8) oa" 1.181" (90 am.) Ling Lensth toi" (267 na.) lost" (27 am.) Lining Width 1.960" (50 mm.) 2.282" (60m) Lining Thickness 190" nm) 196" (om. Area of one Lining 19,362 sq. in. (125 em 2) , 23.235 sq. in. (150 em 2) : Drum Inside Diameter | 10.090" (255 mm.) 10.030" 285 am.) Dru Overall With 2758" (70 mm.) 2246" (65 mm.) Drum nse With 2.362" (60mm) 2.785"_(70 a.)BRAKES rake Shows Adivstm 6 Aiter checking thatthe linings are not 5a rayeing against the drums, install Eas pins and tighten the lock Tack wheels clear of floor. 2- Using ¢ wrench, rotate one of adjust= Ing squares in the same direction the ‘wheel rotates in forward motion until the drum ie locked. 3+ Slightly rotate the adjusting square in the opposite diection until all interference between hos and deun has disappeared, 4- Proceed as above for the other ad justing square of the same wheel. § - Use the same procedure for the front wheel. Mointenonce Since the front wheels are dynamically ‘nd stetically Balanced on the ca, it = advisable to mark the wheel and the drun according to the hub, before Keep hands clean while handling Joke shoes, Do not permit oll of sreaseto come in contact with linings. Keep brake pars, such as rubber cups, jstons, rubber bocts, flexible hose, ‘away from petroleum products (gaso- line, ol, ete) Clean all parts thoroughly with aleokol For the rear wheels, proceed aa akove before installation, Before washing for the front adjustment square. Rotate parts, hands must be cleaned with e rear adjustment square in the oppo- soup and water. (Do not wash hands tion: i.e, towards the rear. {in gasoline or cil.) Before installing new rubber cups in a ‘wheel cylinder, check the bore care fully. Rep! fed cylinder lock nut of each roar = pees Before installing the broke shoes, pcre chock the adjusting sqsores for free . . rotation and luke ghten each yoke a few tums over 7+ At the time of installation, lubricate rod of each cable. new hydraulic parts with brake fluid. yokes to the equal- 8 Lubsicate hand brake cables before installing shoes.REAR SUSPENSION Contents... ee ++ Section Description oe eee Fear Shock Absorber Removal 22 Rear Shock Absorber Installation . " 92 FReor Spring 3 DESCRIPTION The 404 is supported at the rear by coll springs and telescopic shock absorbers, The double-acting shock absorbers are sealed units which require no periodic maintenance. Lateral alignment is assured by @ stabilizing bar hinged to the ele housing at the left and to the body shell at the right. onREAR SUSPENSION Rear Shack Absorber Removal 11 From the floor of the rear deck, remove the duat cover (1) 2 Hold the end of the tod by the flat por- tion on the end and loosen the self Todking nat (2) 3+ Remove the plate washer (3) and the fubber bushing (4). 4+From the lower end ot the rear axle tube remove the selocking mut (2). 5- Remove the plate washer (3) and rubber bushing (4). 1 Place a rubber bushing (4) on each end of the shock absorber 2+ Insect the upper end into Ite position ugh the rear floor mount 3+ Install a rubber bushing (4) and plate washer (3). 4-Use 2 new selflocking nut (2) ond torque to 15 ft Ibs. holding the rod by its flat portion NOTE: The shaft should extend from the 3p of the nut 3/8 inchs 5 Extend the shock until the rubber bush- ing seats onto the rear arle tube mount. 6+ Install a rubber bushing (4) and plate wosher (3) 7 Use a new self-locking mut and torque to 18 &. Ibs. B-JInstall the dust cover over the topREAR SUSPENSION 83 Ree ‘The rect spring is produced in two tensions Identified by one or two green dashes painted on the spring. Spring with one green dash: Free Helght = 16-5/16"" Height under 700 Ibs. 9-7/16"" to 3 1/6" Spring with two green dashes: Free Height = 165/16" Height under 700 Ibs. = 11/16 to 9-7/8" NOTE: The let ond right sorings of vehicle snuat beat the some markings Upon installation, the end of the bot- jon coil should be positioned toward the rear. st rebound blocks secured to the axle housing limit spring com pression and prevent bottoming.