406oc.co.uk

Hi
My 406 Hdi failed its MOT, split cv boot which i can fix myself and secondly the the handbrake failed because it was 13% efficiency the tester said the handbrake should be 16% and above. So it sounds like it needs to be another click tighter. I'm going to have another go at it with Jaspers how to guide. The strange thing is when its been mot'd before its always gone through no problem and the handbrake still feels about the same as it did last year. I did have a go at adjusting it up last weekend and it did tighten it up a lot but it seems to have gone back to what it was before. Has anyone had this problem before? I think later on this year i'll get the handbrake shoes, discs & pads replaced and maybe a new set of back cables as well. Just need to get this through the mot as i've got another peugeot here to fix and mot. Its never ending. The cv boot has a small split in it must only be about 2mm i've had to bodge it until i can put the new one at the weekend i put a small blob of superglue on the split and then put a smear of silicone sealant on top and it seems to be holding ok. The split is right on the edge where the cv boot sits on the cv joint. I'm surprised its split as it was only fitted a month ago and its a stretch boot i bought off ebay so might ask for money back the new one i've bought cost nearly £10 but the quality of it is a lot better. Any advice on the handbrake would be helpful as i don't have enough time to get the garage to adjust it which would have been the quickest option.....

You couid just ajust the shoes,
or quick way just tighten the cable Middle of car Rear,

When mine failed, I replaced all three cables, it passed, but it's still crap, always leave her parked in gear.

Hi
Thanks for the advice I'll have a fiddle with the adjuster at the rear of the car tommorow, i think it needs to be rock solid on 5-6 clicks to pass. Thats what it was before. right now its 7-8 clicks so it shouldn't need much adjustment.

I think the cables may be a bit stretched so that will be another job along with shoes, discs & pads. The cables aren't too expensive though.

I was shocked the other week when I read my MOT pass for the handbrake was only 25% I too always leave it in gear, but a pass at 13%

might sound silly but as the cables age they tend to stick in the casing at the wheels. spray lube into the casing when you adjust it and will loosen up bringing back the efficiency. did it with mine and went from 16% to 20%. just a thought. ps it helps to pull on the handbrake lightly when driving at about 10mph to clear any dust build up too.

hi

Just spent most of the afternoon sorting the handbrake out. Its now rock solid on 4 clicks after using Jaspers how to guide. I was very surprised as its been 5-6 clicks for the last 5yrs. I've had a look at the handbrake shoes today and i think i'll have to replace them as they are worn more on one side than the other. The backplate on n/s/r is a real mess. I've scraped more rust out with a thin screwdriver and tapped them back with a chisel they seems to be getting worse even though i clean them up with a wire wheel patch the holes with fibreglass and give them a good coat of paint. Theres still a very slight rubbing noise but i can live with that.

If anyone else is thinking of doing their handbrake give yourself plenty of time to do it if its your first time. Make sure you soak the handbrake adjuster at the rear in plenty of wd40 or penetrating oil. Give it a good clean up with a wire brush and when the jobs done put some copaslip or LM grease on it. Also clean the handbrake up and put some Lm grease on the moving bits. Makes life a lot easier for next time. I'll let you know how i get on tommorow MOT re-test.

Good luck with the Mot marco,
ive tightend mine up about 3 times now it just goes back to how it was after a month or so,
My guess is the inner disc where the shoes bite is faded ,
iwill have to replace the shoes pads and discs ithink,

the handbrake as always been crap but Mot tester as never said anything, imust of just got lucky on the day
or tester had Won at the Bookies or something,

hi
The handbrake shoes on mine have more on one side than the other so i sanded it back a bit to equal it out and gave the insides of the discs a good clean with a small wire wheel and some brake cleaner. Even when they are new there isn't much on them. Just have to bite the bullet and get new shoes eventually. Funds are a bit tight just now So far i've spent £290 - new cambelt,tensioners, waterpump and coolant, £47 - new tyre, £54 - mot plus just paid out £115 for 6 months road tax. So thats about £500 so far and now the crankshaft pulley is on the way out after about 18 months and 20k .

I'm looking into a solid pulley now made by corteco/hutchison. Theres a bloke on ebay selling them he reckons the one he's selling is the same as the one the main dealers sell. The usaul crankshaft pulley is a two piece rubber and metal part with a damper in the middle part no 0515p2 the one he is selling is the latest solid specification 0515v6 which has a spring inside it. Heres the link for anyone who's interested: http://cgi.ebay.co.uk/406-2-0-HDi-Crank ... _546wt_905

I know the one I had from the stealer was a 515V6

Hi
The 406 passed its mot the tester asked me what i had done to the handbrake! I think he was quite shocked it was 100% better than the original test. I asked the tester what efficiency it was now he said he didn't bother as it was that good it pulled really hard when he tested it. I'm quite happy now another years ticket and the 406 keeps plodding along.

The failing crankshaft pulley is the next job on the list. I sent an email off to Corteco/Hutchison who manufacture and supply Peugeot with these new pulleys here is the reply i got a few people on here might be interested i'm quoting word for word first part is my questions second part is the reply:-

I was wondering if you could help me. Just a technical question. I have a peugeot 406 hdi 110 on a 2000 plate (w reg). The crankshaft pulley has failed after only 18 months/ 20k. I have seen a crankshaft pulley made by your company which is equivalent to part no 0515v6. Dimensions are 162 x 30 EP37 and has 6 v grooves . I have seen this item advertised as a solid pulley for want of a better phrase and according to some info i've read about it this new improved version is supposed to be a solution to the massive failure rate of the 2 piece pulley part no 515P2 that most people have on their 406's. I belong to a 406 owners club and this seems to be a real problem for most 406 owners. My question is will this fit my car and what sort of time period or mileage will this part achieve before failure and does this part produce more noise or vibration than a normal pulley? I am very interested in this part because it does sound like a solution to a major problem.

80000873 the equivalent of PSA’s 0515.V6 is a direct replacement for 0515.P2. The new version does not have the three partial cut outs and is a lot more reliable. The warranty period is 12 months or 10,000 miles whichever is sooner and it will not cause more noise or vibration than the previous version. All that said, this part still has a higher return rate than most, but the common fault now is they are sometimes not balanced correctly and can be seen to be “running out of true” as some garage mechanics write on their reports. These faulty ones are removed and replaced by another before the car leaves the garage.

Saying that the new version is “Solid” is purely because of its looks, it is still a two piece pulley. As mentioned above it no longer has the cut outs along the edge of the side facing away from the engine, but it is still “de-coupled” meaning that the drive from the crankshaft is separated from the outer belt by a centre of bonded rubber and a Teflon sheet protecting the inner fixing from the outer case.

I hope this answers your query.

Best regards,

Neil Woolley
Corteco Ltd

So there you have it even this part has a high return rate but it sounds like its due to bad fitting more than the quality of the pulley. They only guarantee it for a year so it doesn't inspire much confidence that this would last longer than the budget pulley. Hope this helps as i thought this would be worth looking into.

Re: http://cgi.ebay.co.uk/406-2-0-HDi-Crank ... _546wt_905

Thats the same pulley as whats on mine,
ialways thought it was A solid one, but after having a nosey at it the other day theres a rubber band .
there pretty good tho its been on the car a good 8mth no noise from it,

ithink it was in the Region of £1oo or more so ithink the one on the link is a good reasonable price compared to counter prices,
At first ithought the one on mine was fubard but it turned out all the Racket was coming from the lower engine mount Deterioated so it was vibrating metal on metal ,

I have 406 2.0 hdi 90 disk rear brake. The side cables fray/wear where they chafe at the mid-mounting points and then cable outers rust which makes handbrake less efective .
I have just been through all this 3 new cables,shoes,degrease - still rubbish , and ended up building up the handbrake shoe expander mechanism with a bit of weld.
The expander is what the cable fits into and is maybe only 2mm thick on each side of the pivot point - where it wears. Also it wears at the ends where the shoes fit on. The trouble is that you cannot really tell how worn it is - unless you compared it next to a new one !
If you can move it up and down between the shoes with cable relaxed I guess you have some wear.
If you build the expander up too much you can simply cut the brake shoe slots deeper which are a bit shallow anyway.- using thin cutting disk/angle grinder until the shoes touch/nearly touch the stop on the backing plate. If it's too big the disk won't fit !!!
When the handbrake cable is pulled the expander only moves a few mm, so wear in the expander has a noticable affect and clearly the harder you pull the hand brake more wear occures.
My local dealer closed lately so I haven't found out how much these parts cost.

I know this is a zombie thread but I hope this helps someone. My 406 has 227k and got 195 on each side 26% - it struggled to get 80 when it failed and got (40 and 195) on 2nd try then 2 x 195 after weld.