Change a servo on Peugeot 406?

Answer 1

I used this process on my 2002 406 HDI Rapier 2ltr as my pedal became hard to press and took a few seconds for the pedal to depress enough for the brakes to work.

Be sure that it is the servo that needs replacing before you go down that route, first make sure that the vac pump is working and that none of the vac hoses are leaking, a faulty vac pump is by far easier to replace than a servo. Should it be determined that it is deffinately the servo than you are in for a tough job. firstly clear the area by removing air ducts and the throttle housing. Before removing the 2 hydraulic pipes from the master cylinder i would either have some rubber bungs to hand to plug the holes or drain the tank on the master cyliner or you are in for a mess. once you have removed the master cylinder you need to remove the 4 bolts at the back of the servo and they are very tricky, i used ratchet spanners with flexible heads on (from Aldi) and they were perfect for reaching in and removing the top 2 bolts. then jack up front near side (passenger side) and secure with an axle stand and remove the front near side (passenger side) wheel, this will allow to to gain access to the bottome 2 bolts from underneath, you will have to pop off a plastic cover from under the servo mount. You can then access the 2 bolts and securing pin. So long as all air ducts have been removed the servo should pull freely away, reverse the process for refitting and then bleed the brakes through. Expect alot of spanner rash from this as there are alot of tight spaces.