Peugeot 205 - Manual (Page 157)

9 Prise the seal from inside the cylinder,
taking care not to damage the cylinder wall.
10 If required, dismantle the sliding guides.
On the Bendix type unbolt the endplate from
the guides and remove the rubber dust
covers. Keep the guides identified for
location.
11 Clean all the components using
methylated spirit or clean brake fluid then
examine them for wear and damage. Check
the piston and cylinder surfaces for scoring,
excessive wear and corrosion, and if evident
renew the complete caliper assembly.
Similarly check the sliding guides. If the
components are in good condition obtain a
repair kit which will contain all the necessary
rubber seals and other renewable items.
12 Dip the new seal in fresh brake fluid then
locate it in the cylinder groove using the
fingers only to manipulate it.
13 Dip the piston in brake fluid and insert it in
the cylinder, twisting it as necessary to locate
it in the seal.
14 Fit the dust cover and ring over the end of
the piston and cylinder.
15 Lubricate the sliding guides with the
grease supplied and refit them, together with
the new seals. On the Bendix type refit the
endplate and tighten the bolts.
16 On the Bendix type, refit the caliper frame
and tighten the bolts.
Refitting
17 To refit the caliper, first screw it onto the
flexible hose and locate it over the brake disc
so that the hose is not twisted.
18 Clean the mounting bolt threads and
apply locking fluid. Insert the mounting bolts
or upper guide bolt and tighten to the
specified torque.
19 Tighten the flexible hose union on the
caliper. Check that the hose is clear of the
strut and surrounding components and, if
necessary, loosen the rigid pipe union on the
body bracket, reposition the hose and
retighten the union.
20 Refit the brake pads, as described in
Section 4.
21 Remove the brake hose clamp or
polythene sheeting and bleed the hydraulic
system, as described in Section 2.
Braking system 9•9
9
7.4 Brake caliper mounting bolts -
arrowed (DBA Bendix type)
7.7a DBA Bendix type brake caliper components
1 Mounting bolt
2 Caliper assembly
3 Sliding key kit
4 Bleed screw 5 Retaining plate
6 Sliding guide kit with grease
7 Repair kit with grease
7.7b Girling type brake caliper components
1 Mounting bolt
2 Caliper assembly
3 Pad retaining pin and spring
4 Bleed screw
5 Repair kit