405 Mi16 - Bendix ABS brakes failure

Hi,

I'm the lucky owner of a G-reg Peugeot 405 Mi16 with 60,000 miles on
the clock, and I love it to bits. Recently though the brakes have been
playing up and now they have failed completely. There is absolutely no
pedal resistance and I can no longer hear the Bendix "Additional"
motor pumping up the braking system pressure (it's the power-braking
system without a servo). I have replaced the ABS ECU (£120) to no
avail, and I am wondering what the hell to do next.

The Bendix motor does still work - if you touch the ECU contacts
together then the motor runs and the brakes will work fine for about
20 presses, after that the resistance is all gone and there's
obviously no brakes again.

I've even tested the ampage output from the sensor leads and there IS
a difference when the pressure starts to drop, but they do not cause
the ECU to signal the motor to pump up.

Any ideas? I took it to a Peugeout dealer but they were really crap
and couldn't work it out (£50). Know any GOOD mobile mechanics or
Peugeot garages that could help me? Or maybe a specialist brake
centre? I live in Surrey/South London.

Regards
Steve

 

Hi Steve,
Well, i don't know, if your ABS is somewhat identical to the Bendix
ABS in the 605. I have an early 605 with Bendix ABS and have had
problems with it too.

Here is what i have found:
The Bendix ABS unit has two switches. One starts the pump, if the
pressure drops under 160 bar, and one that stops the pump, if the
pressure reaches 180 bar. These switches are located at the pump unit.
The ABS ECU is not involved in this. So even if your ABS is faulty,
there should be enough brake pressure.
I think, that if your pump still works okay (mine did not any longer),
than the switch, that switches the pump on at 160bar should be faulty.

If i is of any help for you, i have the garage manual for the Bendix
ABS for the 605 as a pdf-file. I can sent it via email to you.

Matthias

 

Hi Matthias,

Those switches may be the problem... - are they the the 3 connectors
fixed to the pump unit which have rubber boots covering them? I could
try replacing them with new ones although I did test the output from
them and there is definately an ampage change when the pressure
decreases. Unfortunately I don't know what the correct values should
be so any information you've got would be superb. A copy of the manual
may help.

By the way, the ECU that I replaced is a small, black box about the
size of a snooker ball with a relay inside and connects to the pump
via 4 wires (2 grey and 2 pale blue), plus some other power wires. Do
you have the same unit in your braking system?

Steve

 

Hi Steve,
Yes, my ABS has this ECU box too. It may be, that the Bendix ABS from
the 405 and the 605 are identical. I mail you the manual, maybe you
can see, if it really is identical. At least it should work similar
and so the wiring diagram will help you. Well - there is one catch,
the manual is in german, so the text may be difficult to read.
Two of the connectors you mentioned are for the switches. The third
one is for the ABS electronic, which is seated on the passenger side
of the motor.
I did not explore the Bendix ABS in total. When i figured out, that
the pump was defective, i changed the complete unit. I got one from
another 605 driver with a spare part car. Its not that easy to find a
Bendix ABS, as for the 605 they changed the Bendix ABS system to a
Bosch ABS system in 1993. They can not be mixed.

Good luck,
Matthias

 

Hi
I've got this problem on my mi16, do you still have the pdf file,? If so could you send it me please thanks hardeep