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Peugeot 205 Gti

Peugeot 205 Gti Published: 31st Aug 2018 - 0 Comments - Be the first, contribute now!

Peugeot 205 Gti
Peugeot 205 Gti
Peugeot 205 Gti
Peugeot 205 Gti
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The Pug’s problems are all behind it now – literally hopes owner Chris Manning

JUST to recap on work so far on the Peugeot: I have removed the ill-fitting turbo engine previously installed, repaired the new donor engine which came with a broken cambelt (even though was sold as a runner!) and replaced, after removing the dashboard, the damaged and cut wiring loom supplying feeds to the ECU and multi-pin plugs to the fuse box and instrument panel. Phew.

With the gearbox with new clutch connected to the engine, I have one final job to do before installing the complete new power plant, that of finding out why the rear suspension is seized on one side. I know the previous owner had lowered it by removing the torsion bars and resetting them and hoped the problem might be found there.

I jacked the rear end up overnight hoping that would release it, but to no avail. I then embarked on a partial strip of driver’s side suspension arm that was seized but the only way I could get any movement on the arm was by placing a scissors jack between body and arm to force it down and trolley jack to force it back up again.

Removal of the torsion bar proved impossible as I could not tell in which position the suspension arm that the torsion bar connects to, was ‘at rest’ and not under tension.

Copious amounts of releasing fluid were applied and even leaving it to soak overnight made no impression and I could not apply any heat to the seized part (which is basically a tube within a tube with needle roller bearings at each end), as it was located close to the plastic fuel tank! I had no choice but to remove the complete rear axle to investigate further and make life easier to work on it. Once removed I decided to get brutal with it, and with two helpful people standing on the suspension tube could swing a large sledgehammer onto the suspension arm to hopefully release it.

Movement at last was detected and I kept on swinging that hefty sledgehammer only to find that all I was doing was hammering the arm of the tube, which was still firmly stuck in place! This arm is normally put on the tube with a hydraulic press. It was at this point I decided to call it a day, as I realised the whole lot was past being repaired as the pictures show, with one side still seized and the other the needle rollers have badly damaged the other side.

Thankfully hope was at hand as a phone call to Sam (who co-owns the car with my son Oliver) revealed that his brother used to own several 205 GTis years ago and had a complete rear axle in his lock up garage. Result. A quick inspection revealed it to be in pretty good order, the only problem I encountered was a sheared bleed nipple on the nearside brake calliper. This appears to be a common problem as the calliper is made of aluminium and the small bleed nipple, is steel. I tried to drill it out and retap the thread, but to no avail.

Searching the internet revealed no spare second-hand ones for sale (only a pair at £90), but my previous ownership of a number of old Citroën BX’s years ago, meant I was a frequent caller at a specialist Citroën breakers based in Billericay (Edwards & Son 01277 651486). As Peugeot and Citroën shared a lot of common parts, I took the calliper to them and they had one on the shelf for £25. Another result.

The rear axle was pretty simple to install and took the opportunity to replace the metal brake hoses at the same time as both looked pretty rusty. At last the car is back on its own wheels, without the tyre on the seized side not being millimetres away from the bodywork!

Next job is the big one though. The installation of the new engine and gearbox, but more about that next time in Classic Motoring.

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