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How to change front suspension strut on Peugeot 406 saloon – replacement guide

downloads: 9

Important!

This replacement procedure can be used for:
PEUGEOT 406 (8B) 1.6, PEUGEOT 406 (8B) 1.8 16V, PEUGEOT 406 (8B) 2.0 16V, PEUGEOT 406 (8B) 1.9 TD, PEUGEOT 406 (8B) 2.1 TD 12V, PEUGEOT 406 (8B) 2.0 Turbo, PEUGEOT 406 (8B) 1.9 TD, PEUGEOT 406 (8B) 3.0 24V, PEUGEOT 406 (8B) 1.8, PEUGEOT 406 (8B) 2.0 HDI, PEUGEOT 406 (8B) 2.0 HDI, PEUGEOT 406 (8B) 2.0 16V, PEUGEOT 406 (8B) 3.0 V6, PEUGEOT 406 (8B) 1.8 16V, PEUGEOT 406 (8B) 2.0 16V, PEUGEOT 406 (8B) 2.2 HDi, PEUGEOT 406 (8B) 1.9 D, PEUGEOT 406 (8B) 2.0 16V HPi, PEUGEOT 406 (8B) 2.0 HDi, PEUGEOT 406 (8B) 1.8, PEUGEOT 406 (8B) 2.0 … View more

The steps may slightly vary depending on the car design.

How to change a front shock absorbers on PEUGEOT 406 TUTORIAL | AUTODOC

All the parts you need to replace – Shock Absorber for 406 (8B) and other PEUGEOT models

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Replacement: suspension strut – Peugeot 406 saloon. List of the tools you'll need:

                      Wire brush
                    
                      WD-40 spray
                    
                      Brake cleaner 
                    
                      Copper grease 
                    
                      High-temperature ceramic grease
                    
                      Torque wrench
                    
                      Combination spanner #19
                    
                      Combination spanner #21
                    
                      HEX bit no.H6.
                    
                      Torx bit T50
                    
                      Drive socket # 10 
                    
                      Drive socket # 16 
                    
                      Drive socket # 17 
                    
                      Drive socket # 21 
                    
                      Drive socket # 36 
                    
                      Wheel impact socket #19
                    
                      Ratchet wrench
                    
                      Flat chisel
                    
                      Hammer
                    
                      Pin punch
                    
                      Crow bar
                    
                      Flat Screwdriver
                    
                      Round-nose pliers
                    
                      Ball joint puller
                    
                      Hydraulic strut spring compressor
                    
                      Fender cover
                    
                      Wheel chock

Buy tools

Replacement: suspension strut – Peugeot 406 saloon. Tip from AUTODOC experts:

Both shock struts of the front suspension should be replaced simultaneously.
The replacement procedure is identical for the left and right shock struts of the front suspension.
Please note: all work on the car – Peugeot 406 saloon – should be done with the engine switched off.

Carry out replacement in the following order:

Step 1

Secure the wheels with chocks.
Step 2

Loosen the wheel mounting bolts. Use wheel impact socket #19.
Step 3

Raise the front of the car and secure on supports.
Step 4

Unscrew the wheel bolts.

Replacement: suspension strut – Peugeot 406 saloon. AUTODOC recommends:
To avoid injury, hold up the wheel when unscrewing the bolts.
Step 5

Remove the wheel.
Step 6

Clean the fastener that connects the sway bar link to the suspension strut. Use a wire brush. Use WD-40 spray.
Step 7

Unscrew the fastener connecting the stabilizer link to the shock strut. Use a combination spanner #19. Use HEX No.H6. Use a ratchet wrench.
Step 8

Remove the stabilizer rod.
Step 9

Unscrew the ABS sensor wiring bracket. Use a drive socket #10. Use a ratchet wrench.
Step 10

Remove the bracket from the suspension strut.
Step 11

Clean the fastener connecting the tie rod end to the steering knuckle. Use a wire brush. Use WD-40 spray.
Step 12

Unscrew the end fastening nut to the steering knuckle. Use a drive socket #17. Use a ratchet wrench.
Step 13

Disconnect the tie rod end from the steering knuckle. Use a ball joint puller.
Step 14

Clean the fastener that connects the suspension arm to the ball joint. Use a wire brush. Use WD-40 spray.

Step 15

Unscrew the fastener connecting the ball joint to the suspension control arm. Use a drive socket #21. Use a ratchet wrench.
Step 16

Disconnect the ball joint from the control arm. Use a ball joint puller. Use a crowbar.
Step 17

Remove the cotter pin securing the hub nut. Use round-nose pliers. Use a flat screwdriver.
Step 18

Clean the wheel hub fastener. Use a wire brush. Use WD-40 spray.
Step 19

Unscrew the wheel hub axle nut. Use a drive socket #36. Use a ratchet wrench.
Step 20

Remove the fastening nut.
Step 21

Detach the driveshaft from the steering knuckle. Use a pin punch. Use a hammer.
Step 22

Clean the lower fastener connecting the suspension strut to the steering knuckle. Use a wire brush. Use WD-40 spray.
Step 23

Unscrew the lower fastener connecting the shock strut to the steering knuckle. Use a drive socket #16. Use a ratchet wrench.
Step 24

Remove the fastening bolt.
Step 25

Release the lower fastener connecting the shock strut to the steering knuckle. Use a flat metal-working chisel. Use a hammer.
Step 26

Disconnect the steering knuckle from the shock absorber strut.

Replacement: suspension strut – Peugeot 406 saloon. AUTODOC experts recommend:
Make sure that the steering knuckle is supported.
Step 27

Lower the car.
Step 28

Open the bonnet.
Step 29

Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.
Step 30

Clean the fasteners of the shock strut upper mount. Use a wire brush. Use WD-40 spray.

Step 31

Unscrew the upper fasteners of the shock strut. Use Torx T50. Use a ratchet wrench.

AUTODOC recommends:
Important! Hold the suspension strut while unscrewing the fastening bolts. Peugeot 406 saloon
Step 32

Remove the suspension strut.
Step 33

Set the shock absorber strut on the spring compressor tool.

Replacement: suspension strut – Peugeot 406 saloon. Tip from AUTODOC:
Note that when using a spring compressor, spring coils need to be securely gripped, compressing the spring on the opposite sides.Ensure the correct position of the spring in the retainer.Make sure that the spring coils tightly entered the lock handles.
Step 34

Compress the spring.
Step 35

Treat the shock strut rod. Use a wire brush. Use WD-40 spray.
Step 36

Remove the strut piston rod nut. Use a combination spanner #21. Use HEX No.H6. Use a ratchet wrench.
Step 37

Remove the top strut mount.
Step 38

Release the coil spring.

Step 39

Remove the spring.
Step 40

Remove the shock absorber dust cap and the bump stop.

AUTODOC recommends:
Replacement: suspension strut – Peugeot 406 saloon. Carefully inspect the mount, the boot, and the bump stop of the shock absorber. Replace if necessary.
Step 41

Remove the old shock absorber from the hydraulic coil spring compressor.

Replacement: suspension strut – Peugeot 406 saloon. Professionals recommend:
Before installing a new shock absorber you should pump it manually 3-5 times.
Step 42

Install the dust sleeve and the bump stop on the new shock absorber.
Step 43

Install the new shock absorber on the hydraulic coil spring compressor.
Step 44

Install the spring on the shock absorber.

Step 45

Compress the spring.

Step 46

Install the upper strut mount and the strut mount bearing.
Step 47

Tighten the shock strut piston rod nut. Use a combination spanner #21. Use HEX No.H6. Use a torque wrench. Tighten it to 65 Nm torque.

Replacement: suspension strut – Peugeot 406 saloon. Tip:
Check to make sure the spring is positioned correctly. Avoid its misalignment.
Step 48

Decompress the spring.

Step 49

Remove the assembled shock strut.

Step 50

Install the shock strut into the wheel arch.
Step 51

Secure the upper fasteners of the shock strut.

Replacement: suspension strut – Peugeot 406 saloon. Tip from AUTODOC experts:
To avoid injuries, hold the shock strut when screwing the fastening bolts in.
Step 52

Tighten the upper fasteners of the shock strut. Use Torx T50. Use a torque wrench. Tighten it to 40 Nm torque.
Step 53

Remove the fender protection cover.
Step 54

Close the hood.
Step 55

Raise the front of the car and secure on supports.
Step 56

Treat the shock strut mounting seat on the steering knuckle. Use a wire brush. Use WD-40 spray.
Step 57

Release the lower fastener connecting the shock strut to the steering knuckle. Use a flat metal-working chisel. Use a hammer.
Step 58

Fix the shock absorber strut on the steering knuckle.
Step 59

Install the fastening bolt.
Step 60

Tighten the lower fasteners of the suspension strut. Use a drive socket #16. Use a torque wrench. Tighten it to 55 Nm torque.
Step 61

Install the bracket on the suspension strut.

Step 62

Tighten the ABS sensor wiring bracket. Use a drive socket #10. Use a ratchet wrench.
Step 63

Treat the splines of the driveshaft CV joint. Use a wire brush. Use WD-40 spray.
Step 64

Install the steering knuckle on the CV axle.
Step 65

Attach the ball joint to the control arm.

Step 66

Tighten the fastener that connects the suspension arm to the ball joint. Use a drive socket #21. Use a torque wrench. Tighten it to 45 Nm torque.
Step 67

Install the fastening nut.
Step 68

Tighten the hub. Use a drive socket #36. Use a torque wrench. Tighten it to 325 Nm torque.
Step 69

Install a new hub nut cotter pin. Use a hammer.
Step 70

Ιnstall the transverse stabilizer link.

Step 71

Tighten the fastener connecting the stabilizer link to the shock strut. Use a combination spanner #19. Use HEX No.H6. Use a torque wrench. Tighten it to 65 Nm torque.
Step 72

Connect the tie rod end to the steering knuckle.
Step 73

Tighten the fastening nut connecting the tie rod end to the steering knuckle. Use a drive socket #17. Use a torque wrench. Tighten it to 35 nm torque.
Step 74

Treat the shock strut fasteners. Treat the fastener connecting the tie rod end to the steering knuckle. Treat all joints of the stabiliser link. Treat the ball joint fastener. Use copper grease.
Step 75

Treat the surface where the brake disc contacts the wheel rim. Use high-temperature ceramic grease.
Step 76

Clean the brake disk surface. Use a brake cleaner.

AUTODOC recommends:
Replacement: suspension strut – Peugeot 406 saloon. After applying the spray, wait a few minutes.
Step 77

Install the wheel.

Replacement: suspension strut – Peugeot 406 saloon. AUTODOC recommends:
To avoid injury, hold up the wheel when screwing in the fastening bolts.
Step 78

Screw in the wheel bolts. Use wheel impact socket #19.
Step 79

Lower the car and working in a cross order, tighten the wheel bolts. Use wheel impact socket #19. Use a torque wrench. Tighten it to 90 nm torque.
Step 80

Remove the jacks and chocks.

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