Warning: Renew both sets of rear brake pads at the same time - never renew the pads on only one wheel, as uneven braking may result. Dust created by wear of the pads may contain asbestos, which is a health hazard. Never blow it out with compressed air and don't inhale any of it. An approved filtering mask should be worn when working on the brakes. DO NOT use petrol or petroleum-based solvents to clean brake parts; use brake cleaner or methylated spirit only.
1. Chock the front wheels, then jack up the rear of the vehicle and support it on axle stands (see "Jacking and vehicle support"). Remove the rear wheels.
2. Extract the small spring clip from the pad retaining plate and then slide the plate out of the caliper (see illustrations). Discard the spring clip - a new one must be used on refitting.
5.2a. Extract the spring clip...
5.2b.... then slide out the pad retaining plate...
3. Using pliers if necessary, withdraw both the inner and outer pads from the caliper (see illustration). Make a note of the correct fitted position of the anti-rattle springs and remove the springs from each pad.
5.3. ... and withdraw the brake pads from the caliper
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4. First measure the thickness of the friction material of each brake pad. If either pad is worn at any point to the specified minimum thickness or less, all four pads must be renewed. Also, the pads should be renewed if any are fouled with oil or grease; there is no satisfactory way of degreasing friction material, once contaminated. If any of the brake pads are worn unevenly, or fouled with oil or grease, trace and rectify the cause before reassembly. New brake pads and spring kits are available from Peugeot dealers.
5. If the brake pads are still serviceable, carefully clean them using a clean, fine wire brush or similar, paying particular attention to the sides and back of the metal backing. Clean out the grooves in the friction material and pick out any large embedded particles of dirt or debris. Carefully clean the pad locations in the caliper body/mounting bracket.
6. Prior to fitting the pads, check that the guide sleeves are free to slide easily in the caliper body and check that the rubber guide sleeve gaiters are undamaged. Brush the dust and dirt from the caliper and piston, but do not inhale it, as it is injurious to health. Inspect the dust seal around the piston for damage and the piston for evidence of fluid leaks, corrosion or damage. If attention to any of these components is necessary, refer to Section 11.
7. If new brake pads are to be fitted, it will be necessary to retract the piston fully into the caliper bore, by rotating it in a clockwise direction. This can be achieved using a suitable square-section bar, such as the shaft of a screwdriver, which locates snugly in the caliper piston slots (see illustration). Provided that the master cylinder reservoir has not been overfilled with hydraulic fluid, there should be no spillage, but keep a careful watch on the fluid level while retracting the piston. If the fluid level rises above the "MAX" level line at any time, the surplus should be siphoned off, or ejected via a plastic tube connected to the bleed screw (see Section 2).
5.7. Retract the piston using a squaresection bar...
Warning: Do not syphon the fluid by mouth, as it is poisonous; use a ZLLA syringe or an old poultry baster.
8. Position the caliper piston so that its piston reference slot (A) is positioned horizontally, above or below the piston groove (B); this is necessary to ensure that the lug on the inner pad will locate with the caliper piston slot on installation (see illustration).
5.8. ... and position the piston so that the reference slot (A) is positioned horizontally above or below the piston groove (B)
9. The brake pad with the lug on its backing plate is the inner pad. Refit the anti-rattle springs to the pads, so that when the pads are fitted in the caliper, the spring end will be located at the opposite end of the pad, in relation to the pad retaining plate (see illustration).
5.9. Inner brake pad can be identified by its locating lug (arrowed). Note the correct fitted positions of the anti-rattle springs
10. Locate the outer brake pad in the caliper body, ensuring that its friction material is against the brake disc. Slide the inner pad into position in the caliper, ensuring that the lug on its backing plate is aligned with the slot in the caliper piston (see illustration).
5.10. Install the inner pad, ensuring its locating lug is correctly engaged in the piston slot
11. Ensure that the anti-rattle spring ends on both pads are correctly positioned, then slide the retaining plate into place and secure it in position with a new spring clip. It may be necessary to file an entry chamfer on the edge of the retaining plate, to enable it to be fitted without difficulty.
12. Depress the brake pedal repeatedly until the pads are pressed into firm contact with the brake disc and normal (non-assisted) pedal pressure is restored. Check that the inner pad lug is correctly engaged with one of the caliper piston slots.
13. Repeat the above procedure on the remaining rear brake caliper.
14. Check the handbrake cable adjustment as described in Chapter 1A or 1B, then refit the roadwheels and lower the vehicle to the ground. Tighten the roadwheel bolts to the specified torque setting.
15. Check the hydraulic fluid level as described in "Weekly checks".
16. New pads will not give full braking efficiency until they have bedded in. Be prepared for this and avoid hard braking as far as possible for the first hundred miles or so after pad renewal.