Peugeot 205 GTI 1.9 - Box 9

Kit 33

Parts of kit

33A Rear axle left mount
33B Rear axle right mount
33C Rear axle cross-tube
33D Rear torsion bar
33E Front torsion bar
JM M 2,0 x 4 x 5 mm (x 3)

33A Rear axle left mount 33B Rear axle right mount33C Rear axle cross-tube33D Rear torsion bar33E Front torsion barJM M 2,0 x 4 x 5 mm (x 3)

Step 1

Fit 33A Rear axle left mount to 33C Rear axle cross-tube.

Fit 31A Rear axle left trailing arm to 33C Rear axle cross-tube and fix with JM screw.

Fit 33D Rear torsion bar to 33A Rear axle left mount.

Fit 33C Rear axle cross-tube and 33D Rear torsion bar to 33B Rear axle right mount.

Fit 33E Front torsion bar to 31A Rear axle left trailing arm.

Fit 32A Rear axle right trailing arm to 33C Rear axle cross tube , 33E Front torsion bar and fix with JM screw.

Assembly drawings

General view

Kit 34

Parts of kit

34A Brake disc ( x2 )
34B Caliper bolts cap ( x2 )
34C Brake caliper ( x2 )
34D Left parking brake lever
34E Right parking brake lever
DP M 1,7 x 3 mm (x 5)

34A Brake disc ( x2 )34B Caliper bolts cap ( x2 )34C Brake caliper ( x2 )34D Left parking brake lever34E Right parking brake leverDP M 1,7 x 3 mm (x 5)

Step 2

Fit 34B Caliper bolts cap to 32C Caliper mounting bracket on the right side.

Fit 34B Caliper bolts cap to 31C Caliper mounting bracket on the left side.

Fit 34E Right parking brake lever to 32C Caliper mounting bracket on the right side.

Fit 34D Left parking brake lever to 31C Caliper mounting bracket on the left side.

Fit 34C Brake caliper to 32C Caliper mounting bracket on the right side and fix with two DP screws.

Fit 34C Brake caliper to 31C Caliper mounting bracket on the left side and fix with two DP screws.

Assembly drawings

General view

Kit 35

Parts of kit

35A Rear axle left base
35B Shock absorber piston
35C Shock absorber spring
35D Shock absorber cylider
35E Outer splash shield
35F Inner splash shield
AM M 1,7 x 3 mm (x 6)
FM M 2,3 x 3 x 5,5 mm (x 2)
MM M 2,3 x 13 mm (x 3)

35A Rear axle left base 35B Shock absorber piston35C Shock absorber spring35D Shock absorber cylider35E Outer splash shield35F Inner splash shieldAM M 1,7 x 3 mm (x 6)FM M 2,3 x 3 x 5,5 mm (x 2)MM M 2,3 x 13 mm (x 3)

Step 3

Fit 35D Shock absorber cylider to 31A Rear axle left trailing arm pin and fix with FM screw.

Fit 35B Shock absorber piston to 35A Rear axle left base and fix with MM screw . Fit 35C Spring on 35B Shock absorber piston.

Fit 35B shock absorber piston into 35D Shock absorber cylinder and then , fit 35A Rear axle left base end on 33A Rear axle left mount pin ( illustrations below ).

Fix 33A Rear axle left mount to 35A Rear axle left base with MM screw.

Fit 35E Outer splash shield to 30A Chassis rear section and fix with three AM screws.

Fit 35F Inner splash shield to 30A Chassis rear section and fix with two AM screws.

Assembly drawings

General view

Kit 36

Parts of kit

36A Rear axle right base
36B Shock absorber piston
36C Shock absorber spring
36D Shock absorber cylinder
36E Outer splash shield
36F Inner splash shield
36G Left parking brake cable
36H Right parking brake cable
AM M 1,7 x 3 mm (x 6)
FM M 2,3 x 3 x 5,5 mm (x 2)
MM M 2,3 x 13 mm (x 3)
BM M 2,0 x 4 mm (x 5)
LM M 2,6 x 4 mm (x 4)

36A Rear axle right base 36B Shock absorber piston36C Shock absorber spring36D Shock absorber cylinder36E Outer splash shield36F Inner splash shield36G Left parking brake cable 36H Right parking brake cableAM M 1,7 x 3 mm (x 6)FM M 2,3 x 3 x 5,5 mm (x 2)MM M 2,3 x 13 mm (x 3)BM M 2,0 x 4 mm (x 5)LM M 2,6 x 4 mm (x 4)

Step 4

Fit 36D Shock absorber cylinder to 32A Rear axle right trailing arm pin and fix with FM screw.

Fit 36B Shock absorber piston to 36A Rear axle right base and fix with MM screw . Fit 36C Spring on 36B Shock absorber piston.

Fit 36B shock absorber piston into 36D Shock absorber cylinder and then , fit 36A Rear axle right base end on 33B Rear axle right mount pin ( illustrations below ).

Fix 33B Rear axle right mount to 36A Rear axle right base with MM screw.

Pre assembled Rear Axle.

Fit 36E Outer splash shield to 30A Chassis rear section and fix with three AM screws.

Fit 36F Inner splash shield to 30A Chassis rear section and fix with two AM screws.

Fit 36A Rear axle Right and 35A Left bases to 30A Chassis rear section and fix with two BM screws from bottom side ( upper illustration ) , and then with two more BM screws from upper side ( lower illustration ).

Lead 36H Right parking brake cable through 32D Handbrake cable holder and fix on 34E Right parking brake lever peg.

Lead 36G Left parking brake cable through 31D Handbrake cable holder and fix on 34D Left parking brake lever peg.

Fit 30A Chassis rear section to 22A Chassis panel and fix with three LM screws.

Lead 36G Left and 36H Right parking brake cables through respective holes in 22A Chassis panel , please pay attention to pass 36H Right parking brake cable through 23B Clamp. Note result on next illustartion.