PeugeotPete tool howto

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Group,

Figured somebody may want this data to put in their "PERSONAL SHOP MANUAL".

505 REAR CROSSMEMBER GUIDE PINS

     It looks sort of like a missle, the shaft is 20mm to fit a 21mm hole. 
The threaded end is 10 X 1.50 X 10 mm. The tapered end comes to a 10mm flat 
point. The length of the taper is 24mm. There is a 10mm hole to put a pin in at 
32mm from the point, so the cross member doesn't drop while you are trying to 
put the nuts on. The overall length of the tool is 145mm.
    Get a 10 X 1.50 X 150mm bolt and a piece of pipe 3/4" OD 130mm long, weld 
the bolt in the pipe and grind the bolt head to a point.

SURGE BOTTLE FOR BLEEDING
    
       Use a windshield washer bottle or something similar and attach a hose 
from the bottle to the radiator. Hang the bottle (use welding rod or coat 
hanger to make a hook.
       The 405 does not have a surge bottle.
       We go to plan 2 or B or what ever. 
       Now plan 2, I had to do this to the Renaults I worked on. Get an old 
radiator cap, and take the spring and such out, to where you have only the lid 
and the rubber seal. Get a metal, screw on type tire valve and take the 
schredder out, drill the cap and install the valve. Attach a hose from the bottle to 
the cap. hang the bottle and go to work.

DBA BRAKE SHOE STEADY SPRING TOOL

       I used a # 1 phillips screw driver, grind the point off and cut a slot 
in the tip end. The tool goes into the spring and the slot sits on a bent 
end, press and unhook the spring from the clip in the backing plate.

STRUT SPRING COMPRESSORS

       The spring compressor I use is made up of one 1/2" steel plate, 6 X 
9", with a 3" hole in the center and two (2) holes on the ends for the bolts, a 
9/16' steel plate, 6 X 9", with a 3 3/4" hole, and a 2 1/2" slot cut in the 
side to go around the shock housing and two (2) holes for the bolts. There is 
two case hardened, thread stock 24" X 3/4" with nuts to match. 

RADIATOR PRESSURE TESTER

       You need to get pressure with a gauge on the system. Get a tire pump 
(hand or 12V ) with a gauge, dump the surge bottle and remove the hose, remove 
the hose from the pump and attach the hose from the radiator.

ACCUMULATOR & FUEL PUMP PRESSURE TESTER

       On testing the accumulator, get some old A/C hoses, cut in half and 
modified the fit (install banjo fittings), then use your A/C manifold gauges. 
Use shop air supply for the pressure.

TRANSMISSION OR ENGINE R & R

       Take a 10 mm "L" shaped allen wrench and cut the short leg to 15 mm 
long, on the long leg, heat and bend to 45 degrees, 30 mm from the short leg 
towards the short leg, this is to break loose the top tranny mount bolt (use a 
1/2" pipe 12-14" long as an extention) once its loose it will almost come out 
with your fingers.
       2ea bolts 12 X 100 X 150 long with at least 80 mm of thread to drop 
the chasses 
       2ea bolts 12 X 100 X 120 long, cut the heads off and cut a screwdriver 
slot in each bolt, for guides for the tranny.
       Cut you 3-4 lengths of coathanger about 4" long to make "S" hooks to 
hold cables, wires and clutch slave cyl out of the way while you work.
       Get a small strap or rope comalong to pull the rear end back and the 
drive shaft out of the tranny.
       Check the junk yard for a "U" joint from a wgn, (good or bad) doesn't 
matter, use it to control the shaft when sliding the transmission in.
       Take a 3" 3/8 drive extention, and file on two (2) flats away from the 
poppet ball, to 10 mm, to fit the oil drain plug.

             REFRIGERANT OIL DIP STICK

       The next time you open your system use a dipstick on the compressor. 
Take a coat hanger and cut a section about 10" long, put a finger loop in one 
end, on the other end measure 30 mm and put a file mark, that is where your oil 
should be with a dry system. Put a second mark at 25 mm, that should be where 
your oil is now, if over that, use a vacuum hose and pull some out. Go 
through the plug on top of the compressor, it will not fall straight because of the 
shaft inside, but let it fall as straight down as it will. This should get you 
as close as possible on the oil. :-)

                WHEEL BEARING LOCK NUT PUNCH'S

        1) unlock punch   take a 1/8" flat punch and grind the tip to a 45 
degree angle
        2) lock punch       take a standard 1/2" center punch and round the 
tip


                84 and up lower ball joint tool

         A Ford fullsize 4wd front hub socket fits The 505 balljoint 
perfectly. That & a 1/2 inch drive impact or breaker bar.

By PeugeotPete