REPAIR GUIDELINES FOR REAR AXLESOF THE MODEL RANGES CITROEN AX AND SAXO; PEUGEOT 106 AND 206 USING THE RUVILLE TOOL SET 1002226

DISASSEMBLING:

8. Measure the shaft offset in the axle tube as shown in sketch 2 and enter in table below.

Stub shaft offset left mm

Stub shaft offset right mm

THE FOLLOWING STEPS MUST BE CARRIED OUT ON BOTH SIDES OF THE VEHICLE:

use protective sleeve for shrinkwrapping only

1

2

Caution! Carefully clean elevating screw and axial bearing and adequately grease before use!

ab

CAUTION: installation should only be carried out by qualified professionals in compliance with the general repair guidelines of the manufacturer!

NECESSARY PRELIMINARY TASKS: • Unfasten the parking-brake cable• Carefully clean the working area of the torsion bar mounts. The vehicle has a groove between the axle tube (sheet metal)

and the axle yoke (cast steel) and it is especially important to clean this well.• Unscrew the hydraulic lines of the brake calipers • Unplug the electric lines to the wheel-speed sensors • Remove the brake calipers• Remove the dampers• Measure the distance between the fender edge and the middle of the wheel hub (this distance serves for check after repair)

1. Unscrew out the plastic plugs (1a) and locating screw (1b) of stabilizer retaining plate (left vehicle side).

2. Screw the M12x1.5x50 screw into the thread of the plug hole, which will lift off the stabilizer retaining plate.

3. Do the same on the right side of the vehicle – loosen the locating screw and pull the stabilizer out to the right.

4. Disassembling the torsion bars: unscrew the retaining screws and remove the eccentric discs; carefully clean the grooves.

5. Mark the position of the torsion bars in their teeth so that you can clearly recognize them later.

6. Force the torsion bar out in the direction of its larger teeth.

7. Pull the radial arms off of the stub shafts (if need be, use the special tools Peugeot No. 0538 and 0539)

9. Slide the protective sleeve No. 1002223 onto the tool screw No. 1002222 and screw the M20x1.5 nut delivered with the kit into the stub shaft with its collar to the vehicle’s outer side (Image 3a).

10. Apply a MAG weld seam to reduce the inner diameter of the stub shaft to a minimum of 24 mm, so that the tools placed inside (screw and nut) cannot be pulled out. After welding, remove the screw with protective sleeve and let it cool off (Image 3b). Caution: Disconnect battery before welding.

11. Select the correct thrust ring according to the size of the stub shaft, push on the stub shaft against the axle yoke and put on the tool as seen in Image 4. Caution: Tool screw must be screwed into the nut a minimum of 10 turns.

12. Now pull out the stub shaft using the tool nut (Image 4). Caution: this requires excessive force; use the appropriate tool! The model ranges AX, Saxo and the 106 also have a race on the stub shaft as a sealing surface. Carefully remove this race and keep it for later.

EBH PSA GB 9990193730

3a

4

3b

13. CAUTION! Check the inner surfaces of the axle tube for usability, clean and grease sparingly.

14. Renew the bearings and sealing rings of the radial arms according to manufacturer specifications. Use grease No. 71174 for the bearings.

15. Apply assembly paste No. 71018 thinly and evenly onto the wide chamfer area of the new stub shaft that needs to be pressed in, and extensively onto the opening of the axle tube.

16. Insert the stub shaft as in Image 5 with the tool kit to the same depth as the offset distance measured above.

NOTE

When inserting the stub, constantly check that it is being inserted parallel to the axle tube. Lightly hitting the middle of the axle tube with a rubber hammer will make insertion easier.

ASSEMBLY:

17. Only for model ranges AX, Saxo, 106: Clean the race removed earlier and tap it back onto the new stub shaft. Re-adjust if needed.

18. Lubricate the axle stub using grease 71174 and mount the axial arms with new bearings.

19. Mount the torsion bars again according to manufacturer specifications. Use the measurements taken earlier and position the torsion bars are correctly.

20. Place the eccentric discs of the torsion bars in the cleaned grooves and tighten them down again with the retaining screws.

21. Remount the stabilizer in reverse order.

22. Check the control marks made at removal and if they do not match, correct the position of the torsion bars.

23. Reinstall the other components in reverse order as well: • Dampers • Brake calipers • Wheel-speed sensors

EBH PSA GB 9990193730

6

1 nut M20x1,5 / DIN 6334 31305

2 axial bearing 51204

3 end piece 1002219

4 thrust pipe 1002216

5 thrust piece 1 1002217

5 thrust piece 2 1002218

6 thrust piece 3 1002220

6 thrust piece 4 1002227

7 jackscrew long: 1002221

- protective sleeve 1002223

- connection sleeve 1002224

- jackscrew short: Screw DIN 961 1002222

5

7

2 26

5

43

2 2 1

move in newstub shaft withpressure pad

To be used as dis-tance pieces during the press-in process

A FILM DETAILING REPAR AND FURTHER

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