Peugeot 308: Removing - refitting : Rear brake caliper

ESSENTIAL : Observe the safety and cleanliness recommendations .

ESSENTIAL : All personnel carrying out work on a vehicle fitted with traction batteries must have received specific electric vehicle training and be authorised to work on these vehicles(observe the regulations in force in the respective country).

1. Parts which must always be replaced

Description	Quantity
Brake caliper support bolt (Electric parking brake)	2( per side)
Brake caliper support bolt (Manual parking brake)	2( per side)
Brake hose	1( per side)

CAUTION : The brake caliper bolts are not always replaced with new bolts ; If the bolts are reused, clean the thread and apply thread lock index "E3" .

2. Tooling

Use the products recommended by the manufacturer .

Workshop equipment :

• A diagnostic tool (Electric parking brake)
• A pedal press
• Piston pushing tool

3. Removing

CAUTION : If the brake fluid reservoir is at maximum level, remove its filter and partially drain the reservoir with the aid of a clean syringe in order to avoid it overflowing.

INTERNAL COMBUSTION DRIVE TRAIN

CAUTION : Perform the operations that are required prior to a disconnection of the ancillaries battery .

Disconnect the ancillaries battery.

PHEV DRIVE TRAIN

CAUTION : Perform the operations that are required before disconnecting the ancillaries batteries .

Disconnect the ancillaries batteries (Following the specific procedure).

Place the pedal press on the brake pedal in order to prevent the discharge of any brake fluid when disconnecting the brake pipes.

Lift and support the vehicle.

Remove the rear wheels.

3.1. Vehicles fitted with an electric parking brake control

CAUTION : Before carrying out any work on the rear braking components, place the rear motorised brake caliper actuator in the removal position ; Using the diagnostic tool.

N.B. : Symmetrical operations.

Disconnect the connector(at "a").

Close rear motorised brake caliper actuator connector ; Using cleanliness plugs.

Remove the brake hose (1)(beware of escaping fluid).

Plug the union and the brake caliper ; Using cleanliness plugs.

CAUTION : Limit the risk of knocks to the rear motorised brake caliper assembly actuator .

Remove :

• The bolts (3)
• The rear motorised brake caliper assembly (2)
• The brake pads
• The sound-deadening pads

Remove :

• The bolts (5)
• The brake caliper (4) support

3.2. Vehicles fitted with a manual parking brake

N.B. : Symmetrical operations.

Uncouple the handbrake cable (at "b").

Detach the parking brake cable from the cable guide(at "c").

CAUTION : Plug the union and the brake caliper ; Using cleanliness plugs.

Remove :

• The brake hose (6)
• The spring (9)
• The plugs (7)
• The brake caliper bolts
• The brake caliper (8)
• The brake pads
• The screws of the brake caliper mounting
• The caliper bracket

4. Cleaning

ESSENTIAL : Do not use compressed air to clean the brakes.

4.1. First possibility

Clean the brake disc and the brake caliper, using an approved brake cleaning product.

Leave to drip dry.

Wipe with a paper towel :

• The brake disc
• The brake caliper

4.2. Second possibility

Use dust removal equipment approved by the manufacturer .

5. Check

Visually check :

• The sealing around the rear motorised brake caliper piston
• That the protective gaiters are in good condition and correctly adjusted
• The wear of the brake discs

Replace any defective parts.

CAUTION : No trace of grease, oil or lubricant can be tolerated on the brake pads.

6. Refitting

CAUTION : Observe the tightening torques.

INTERNAL COMBUSTION DRIVE TRAIN

Tightening torques :

• Braking system
• Wheels

PHEV DRIVE TRAIN

Tightening torques :

• Braking system
• Wheels

6.1. Vehicles fitted with a manual parking brake

N.B. : Symmetrical operations.

Push back the brake caliper piston ; Using a piston pushing tool.

CAUTION : On each removal, always clean the thread of the brake caliper support bolts.

CAUTION : The brake caliper bolts are not always replaced with new bolts ; If the bolts "E3" are reused, clean the thread and apply thread lock index .

Refit :

• The caliper bracket
• The screws of the brake caliper mounting (New)
• The brake pads
• The brake caliper (8)
• The brake caliper bolts
• The plugs (7)
• The spring (9)

Remove the protective caps.

Refit the brake hose (6)(new).

Engage the parking brake cable in the guide (at "c").

6.2. Vehicles fitted with an electric parking brake control

Symmetrical operations.

CAUTION : Limit the risk of knocks to the rear motorised brake caliper assembly actuator .

CAUTION : Do not turn the rear motorised brake caliper piston to push it back.

Push back the brake caliper piston ; Using a piston pushing tool.

CAUTION : At each removal, always clean the thread of the screws (5).

CAUTION : Make sure that the positioning lug (at "f") on the brake pad engages correctly in the recess (at "e") of the piston.

CAUTION : The brake caliper bolts (3) are not always replaced with new bolts ; If the bolts (3) are reused, clean the thread and apply thread lock index "E3" .

Refit :

• The brake caliper (4) support
• The new bolts (5)
• The sound-deadening pads
• The brake pads
• The rear motorised brake caliper assembly (2)
• The bolts (3)

Remove the protective caps.

Refit the brake hose (1)(new).

Reconnect the connector (at "a").

6.3. Common operations

Visually inspect the routing and condition of the brake hoses and pipes.

Remove the pedal press .

Fill and bleed the braking circuit .

Refit :

• The rear wheel
• The vehicle to its wheels

INTERNAL COMBUSTION DRIVE TRAIN

CAUTION : Perform the operations that are required after reconnecting the ancillaries battery .

Reconnect the ancillaries battery.

PHEV DRIVE TRAIN

CAUTION : Perform the operations that are required after reconnecting the ancillaries batteries .

Reconnect the ancillaries batteries (Following the specific procedure).

6.4. Vehicles fitted with an electric parking brake control

Using the diagnostic tool :

• Carry out the rear motorised brake caliper application counter zero reset procedure
• Read and clear the fault codes

6.5. Common operations

ESSENTIAL : Apply the brakes several times, gently and progressively, with the engine running, before driving the vehicle.

Check a few times that the electric handbrake is working properly.

Check the brake fluid level and top up if necessary.