Peugeot 205. Manual - part 39

mounting in a vice and attempting to extend
and retract it. If the resistance is not firm and
even in both directions, or if there are signs of
leakage or damage, the shock absorber must
be renewed.

Refitting

6 Refitting is a reversal of removal, but renew
the self-locking nuts. The nuts must be
tightened when the distance between the
mounting bolt centres is 288.0 mm. The
Peugeot tool 80911 for this operation consists
of a bar and adjustable bolt located beneath
the lifting ramp and hooked on the suspension
tube; however, loading the rear of the car by
trial and error will produce the same result.

11 Rear suspension assembly -

removal and refitting

4

Removal

1 Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and vehicle support”).
2 Remove the handbrake cables, with
reference to Chapter 9.
3 Remove the complete exhaust system, with
reference to Chapter 4D. 
4 Disconnect the flexible brake hoses from
the rear suspension assembly, with reference
to Chapter 9.
5 Unscrew the left-hand rear mounting nut,
remove the exhaust bracket then temporarily
refit the nut.

6 Unbolt and remove the front clamp and
bracket (see illustration), but do not unscrew
the seat belt anchorage (where fitted).
7 Adjust the position of the car on the axle
stands so that the rear wheels are just
touching the ground, then place additional
stands or jacks beneath the suspension tube.
8 Working in the luggage compartment
unscrew the front and rear mounting nuts then
carefully withdraw the assembly from under
the car.

Refitting

9 Refitting is a reversal of removal, but tighten
all nuts and bolts to the specified torque.
When tightening the front clamp make sure
that the ring is centred in the seat belt
anchorage bracket. Refer to Chapter 4D and 9
when refitting disturbed exhaust and braking
system components and bleed the brake
hydraulic system on completion.

12 Vehicle ride height - checking

5

Checking of the vehicle ride height requires

the use of Peugeot special tools to accurately
compress the suspension in a suspension
checking bay.

The operation should be entrusted to a

Peugeot dealer, as it not possible to carry out
checking accurately without the use of the
appropriate tools.

13 Steering wheel - removal and

refitting

2

Removal

1 Set the front wheels in the straight-ahead
position.
2 Prise out the centre pad, then use a socket
to unscrew the retaining nut (see illustration).
3 Mark the hub in relation to the inner column
then pull off the steering wheel.

Refitting

4 Refitting is a reversal of removal, but check
that the steering wheel is correctly centred
with the front wheels straight ahead. Tighten
the nut while holding the steering wheel rim.

14 Steering column and lock -

removal and refitting

4

Removal

1 Remove the steering wheel, (Section 13).
2 Remove the lower trim panel from under the
steering column (see illustration).
3 Mark the column lower universal joint in
relation to the intermediate shaft then
unscrew and remove the clamp bolt (see
illustration).
4 Remove the combination switches, as
described in Chapter 12.
5 Disconnect the ignition switch wiring
connectors.
6 Unscrew the mounting nuts and bolts,
disconnect the inner column from the
intermediate shaft, and withdraw the steering
column from the car. Where shear bolts are
fitted they must be drilled to remove the
heads, then unscrewed after removing the
column.

Suspension and steering  10•7

10

10.2  Rear shock absorber bottom

mounting

11.6  Rear suspension cross-tube front

clamp and seat belt anchorage

13.2  Steering wheel retaining nut

14.2  Steering column lower trim panel

screws (arrowed)

14.3  Steering column lower universal joint

and clamp bolt (arrowed)

If the wheel is tight, tap it up
near the centre, using the
palm of your hand, or twist it
from side to side, whilst

pulling upwards to release it from the
shaft splines.

7 If necessary, the intermediate shaft can be
removed after prising out the grommet and
unscrewing the bottom clamp bolt (see
illustration).
8 To remove the steering lock, unscrew the
retaining bolt then, with the ignition key
aligned with the small arrow between the ‘A’
and ‘M’ positions, depress the plunger in the
housing and withdraw the lock (see
illustration). 

Refitting

9 Refitting is a reversal of removal.

15 Steering gear - removal and

refitting

4

Manual steering gear

Removal

1 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and vehicle support”). Remove
the front roadwheels.

2 Unscrew the track rod end locknuts then
use a separator tool to detach the track rod
end balljoints from the hub carrier steering
arms.
3 Mark the lower column in relation to the
pinion on the steering gear. 
4 Unscrew and remove the column-to-pinion
clamp bolt. 

5 Unscrew and remove the two mounting
bolts and withdraw the steering gear from one
side of the subframe (see illustration). 

Refitting

6 Refitting is a reversal of removal, but tighten
all nuts and bolts to the specified torque. On
completion, have the front wheel toe setting
checked (see Section 21).

Power-assisted steering gear

Removal

7 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and vehicle support”). Remove
the front roadwheels.
8 Prepare a suitable container, then
disconnect the fluid pipes from the steering
gear, and allow the fluid to drain into the
container.
9 Unscrew the track rod end balljoint
locknuts, then use a separator tool to detach
the track rod end balljoints from the hub
carrier steering arms.
10 Mark the lower column in relation to the
pinion on the steering gear.
11 Unscrew and remove the
column-to-pinion clamp bolt.
12 On manual transmission models,
disconnect the three gearchange control rods
from the levers on the transmission.
13 Extract the spring clip from the
gearchange linkage (see illustration), then
unclip the transmission selector and

10•8 Suspension and steering

14.7  Steering column intermediate shaft

(arrowed)

14.8  Steering column and lock assembly

components

1 Bolt
2 Steering lock and ignition

switch

3 Steering column
4 Mounting nut
5 Clamp bolt and nut

15.5  Steering gear mounting bolt locations (arrowed)

engagement rods, and support them in an
upright position out of the way, using wire or
string.
14 Remove the two steering gear securing
bolts, and recover the spacer tubes from the
subframe, then disconnect the steering gear
pinion from the steering column shaft.
15 Support the front subframe using a trolley
jack and interposed block of wood positioned
under the subframe crossmember.
16 Remove the four bolts securing the rear of
the subframe to the body, and the two nuts or
bolts, as applicable, securing the front of the
subframe to the body (see illustration). Also
remove the nut and bolt from the lower engine
mounting.
17 Carefully lower the subframe sufficiently

to enable removal of the steering gear,
ensuring that the subframe is adequately
supported.
18 Rotate the steering gear towards the rear
of the vehicle, and withdraw the assembly
over the rear of the subframe, taking care not
to damage the rack bellows.

Refitting

19 Refitting is a reversal of removal, bearing
in mind the following points:

a) Ensure that the spacer tubes are fitted to

the steering gear securing bolts.

b) Tighten all fixings to the specified torque.
c) Ensure that the marks made on the

steering gear pinion and the lower column
during removal are aligned.

d) When reconnecting the fluid pipes to the

steering gear, the high pressure fluid pipe
must be vertical (see illustration).

e) Secure the hose to the high-pressure fluid

pipe using a cable-tie.

f) Check the gearchange mechanism for

correct operation after reconnecting the
linkages.

g) On completion, bleed the power steering

hydraulic system as described in Section
17, and have the front wheel toe setting
checked (see Section 21).

16 Steering gear rubber bellows

- renewal

3

1 Remove the relevant track rod end, as
described in Section 19.
2 Release the clips from each end of the
bellows then ease the bellows from the
steering gear and pull it from the track rod.
3 Clean the track rod and bellows location on
the steering gear.
4 Slide the new bellows onto the track rod
and steering gear, check that it is not twisted,
then fit the clips.
5 Refit the track rod end with reference to
Section 19.

17 Power steering system -

bleeding

1

1 This procedure will only be necessary when
any part of the hydraulic system has been
disconnected.
2 Referring to “Weekly checks”, remove the
fluid reservoir filler cap, and top-up with the
specified fluid to the maximum level mark.

Suspension and steering  10•9

10

15.13  Extract the spring clip (6) from the gearchange linkage

15.16  Front subframe attachments

9 Rear securing bolts
10 Front securing bolts

11 Lower engine mounting nut

15.19  Correct refitting of power assisted steering gear

1

High-pressure pipe

3

Column-to-pinion clamp bolt

10

Hose secured with cable tie

3 With the engine stopped, slowly move the
steering from lock-to-lock several times to
purge out the trapped air, then top-up the
level in the fluid reservoir. Repeat this
procedure until the fluid level in the reservoir
does not drop any further.
4 Start the engine, then slowly move the
steering from lock-to-lock several times to
purge out any remaining air in the system.
Repeat this procedure until bubbles cease to
appear in the fluid reservoir.
5 If, when turning the steering, an abnormal
noise is heard from the fluid lines, it indicates
that there is still air in the system. Check this
by turning the wheels to the straight-ahead
position and switching off the engine. If the
fluid level in the reservoir rises, then air is
present in the system, and further bleeding is
necessary.
6 Once all traces of air have been removed
from the power steering hydraulic system,
turn the engine off and allow the system to
cool. Once cool, check that the fluid level is
up to the maximum mark on the power
steering fluid reservoir, topping-up if
necessary.

18 Power steering pump -

removal and refitting

3

Removal

1 Remove the alternator as described in
Chapter 5A.
2 Prepare a suitable container, then
disconnect the fluid hoses from the pump,
and allow the fluid to drain into the container.
3 Unscrew and remove the power steering
pump mounting bolts, then withdraw the
pump.

Refitting

4 Refitting is a reversal of removal, but on
completion, tension the drivebelt as described
in Chapter 1, and bleed the power steering
hydraulic system as described in Section 17.

19 Track rod end - removal and

refitting

3

Removal

1 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and vehicle support”). Remove
the relevant front roadwheel.
2 Loosen the locknut on the track rod end by
a quarter of a turn.
3 Unscrew the balljoint locknut and use an
extractor tool to separate the balljoint tapered
shank from the hub carrier steering arm (see
illustration).
4 Unscrew the track rod end from the track
rod, noting the number of turns necessary to
remove it. Remove the locknut from the track
rod end threads.

Refitting

5 Screw on the locknut then screw the new
track rod end the same number of turns onto
the track rod.
6 Clean the taper surfaces then fit the
balljoint shank to the hub carrier steering arm
and tighten the nut to the specified torque.

7 Tighten the locknut on the track rod end.
8 Refit the roadwheel and lower the car to the
ground.
9 On completion, have the front wheel toe
setting checked (see Section 21).

20 Track rod - removal and

refitting

4

Removal

Note: A new inner balljoint lockwasher must
be used on refitting.
1 Remove the track rod end as described in
Section 19.
2 Release the retaining clips and slide the
rubber bellows off the end of the steering gear
housing and track rod (see illustration).
3 Unscrew the track rod inner balljoint from
the steering rack end, preventing the steering
rack from turning by holding the balljoint
lockwasher with a pair of grips. Take great
care not to mark the surfaces of the rack and
balljoint.
4 Remove the track rod assembly, and
discard the lockwasher - a new one must be
used on refitting.
5 Examine the track rod inner balljoint for
signs of slackness or tight spots, and check
that the track rod itself is straight and free from
damage. If necessary, renew the track rod.

Refitting

6 Locate the new lockwasher assembly on
the end of the steering rack, and apply a few
drops of locking fluid to the track rod inner
balljoint threads.
7 Screw the balljoint into the steering rack,
and tighten it to the specified torque whilst
retaining the lockwasher with a pair of grips.
Again, take great care not to damage or mark
the track rod balljoint or steering rack.
8 Carefully slide on the rubber bellows, and
locate it on the steering gear housing. Turn
the steering fully from lock-to-lock, to check
that the gaiter is correctly positioned on the
track rod, then secure it in position with new
retaining clips.
9 Refit the track rod end as described in
Section 19.

10•10 Suspension and steering

19.3  Separating the track rod end from the

hub carrier steering arm

1 Bellows
2 Lock washer
3 Track rod

4 Locknut
5 Track rod end

20.2  Track rod components

If difficulty is experienced in
loosening or tightening a
balljoint taper pin nut due to
the taper pin turning in the

eye, apply pressure with a jack or long
lever to the balljoint socket to force the
taper pin into its conical seat.