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Peugeot 205 GTI 1.9 - Box 9
BOX 9 - Kits 33-34-35-36
Kit 33
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The parts of kit 33
- 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)
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Step 1
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Fit 33D Rear torsion bar to 33A Rear axle left mount.
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Fit 33C Rear axle cross-tube and 33D Rear torsion bar to 33B Rear axle right mount.
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Fit 33E Front torsion bar to 31A Rear axle left trailing arm.
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Fit 32A Rear axle right trailing arm to 33C Rear axle cross tube , 33E Front torsion bar and fix with JM screw.
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Assembly drawings
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General view
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Kit 34
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The parts of kit 34
- 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)
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Step 2
Fit 34B Caliper bolts cap to 32C Caliper mounting bracket on the right side.
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Fit 34B Caliper bolts cap to 31C Caliper mounting bracket on the left side.
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Fit 34E Right parking brake lever to 32C Caliper mounting bracket on the right side.
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Fit 34D Left parking brake lever to 31C Caliper mounting bracket on the left side.
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Fit 34C Brake caliper to 32C Caliper mounting bracket on the right side and fix with two DP screws.
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Fit 34C Brake caliper to 31C Caliper mounting bracket on the left side and fix with two DP screws.
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Assembly drawings
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General view
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Kit 35
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The parts of kit 35
- 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)
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Step 3
Fit 35D Shock absorber cylider to 31A Rear axle left trailing arm pin and fix with FM screw.
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Fit 35B Shock absorber piston to 35A Rear axle left base and fix with MM screw . Fit 35C Spring on 35B Shock absorber piston.
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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 ).
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Fix 33A Rear axle left mount to 35A Rear axle left base with MM screw.
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Fit 35E Outer splash shield to 30A Chassis rear section and fix with three AM screws.
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Fit 35F Inner splash shield to 30A Chassis rear section and fix with two AM screws.
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Assembly drawings
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General view
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Kit 36
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The parts of kit 36
- 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)
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Step 4
Fit 36D Shock absorber cylinder to 32A Rear axle right trailing arm pin and fix with FM screw.
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Fit 36B Shock absorber piston to 36A Rear axle right base and fix with MM screw . Fit 36C Spring on 36B Shock absorber piston.
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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 ).
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Fix 33B Rear axle right mount to 36A Rear axle right base with MM screw.
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Pre assembled Rear Axle.
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Fit 36E Outer splash shield to 30A Chassis rear section and fix with three AM screws.
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Fit 36F Inner splash shield to 30A Chassis rear section and fix with two AM screws.
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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 ).
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Lead 36H Right parking brake cable through 32D Handbrake cable holder and fix on 34E Right parking brake lever peg.
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Lead 36G Left parking brake cable through 31D Handbrake cable holder and fix on 34D Left parking brake lever peg.
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Fit 30A Chassis rear section to 22A Chassis panel and fix with three LM screws.
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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.
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Note 36G Left and 36H Right parking brake cables fit through respective holes in 22A Chassis panel.
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36G Left and 36H Right parking brake cables exiting on upper side of 22A Chassis panel.
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Lead 25F Rear right brake line through 32F Brake line holder.
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After 32F Brake line holder , lead 25F Rear right brake line via 32E Brake line holder and fit to 34C Brake caliper peg.
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Lead 25E Rear left brake line through 31F Brake line holder.
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After 31F Brake line holder, lead 25E Rear left brake line via 31E Brake line holder and fit to 34C Brake caliper peg.
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Final close up view.
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Assembly drawings
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General view
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