[Peugeot-L] 405 front end overhaul

From: Raminder Malik <raminder_at_touchtelindia.net>
Date: 05/07/05


Hi everyone,

I have finally got down to something which I have been putting off for a very long time. The car is is a 1991 405 with an XUD7T (1769cc Turbo Diesel) engine, and 70K miles on the clock.

There have been a number of minor coolant leaks from the numerous hoses over the past one year, which have been attended to post facto. I finally decided to go in for a long term solution. Today I got the the entire engine (with head) and gearbox removed. All the hoses, and all related compnents will be checked and renewed as required.

Removing the entire engine and gearbox from the engine bay provided me with a very exciting opportunity. The entire front suspension and power steering assembly are now visible and accessible in all their glory, and I have decided to get them overhauled. I have a few questions...

  1. Power Steering Rack - The boots are torn, so that is as obvious fix. What are the other things in the assembly I should check/replace ? Condition of the rods? Any bushes? The power steering works fine, there are no leaks, but I feel road bumps in the streeing wheel, and the power steering pump belt squeaks at extreme left/right turns.
  2. Front suspension - I will replace all the bushes, tie rod ends, drop links, balljoints etc. Members on this list have mentioned that suspension bushes should be tightened with the full weight of the car on the wheels/suspension. My question is - what if I get all the suspension components fixed and tightened without the engine in the car. It is much easier, but will it affect the longevity of the new bushes?
  3. Sway Bar - The Haynes manual says the the sway bar has to be adjusted by a Peugeot workshop. What is involved in this. and can it done without Peugeot involvement?
  4. Front springs - I am getting the struts replaced, but what about te springs? Is there a way to check if they are OK? Uncompressed height? Hight with "X" lbs load etc.?

Any other tips that any of you have on any aspect of a suspension/steering overhaul? Or anything else that cas be easily overhauled once the engine and the gearbox are out of the car?

Thanks and regards
Raminder Malik
Delhi, India

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