Directory

1. Introduction

1.1. Background

1.2. Repair is possible!

2. The advantages

2.1. Advantages of the OPTIMAL repair kit

2.2. Advantages of the OPTIMAL tool

3. The PSA repair kits

4. Assembly instructions

4.1. Preliminary work to be carried out on the vehicle

4.2. Removal

4.2.1. Removal for the inside diameter of 26 millimeters

4.2.2. Removal for the inside diameter of 28 millimeters

4.2.3. Removal for the inside diameter of 34 millimeters

4.3. Installation

5. Further information

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1. Introduction

In the case of older PSA Group models, defective rear axles can mean a total write-off since the
manufacturer's recommendation to exchange the rear axle is usually too expensive to implement.
But this is now a thing of the past. PSA rear axle repair kits by OPTIMAL now make efficient and
economical repair possible.

1.1. Background

Peugeot and Citroën vehicles (for models, see table on p.2) were long fitted with torsion-bar rear axles.
This meant the chassis components could be arranged in a space-saving manner. However, the
weakness of this lies in the bearing support of the trailing arm. Increased mechanical
wear occurs in the support and on the stub shaft, while the sealing material
becomes hard and brittle, making it impossible to prevent water from
entering the bearing points. Worn bearings and corroded stub shaft are
the result. The defective support causes noise and a tilting of the rear
wheels becomes visible, with serious consequences for the vehicle's
safety on the road.

In such cases, the manufacturer prescribes a complete exchange of the rear axle. And this, for most
vehicles, means a complete write-off.

1.2. Repair is possible!

It is cheaper and more efficient to repair the rear axle
using the new PSA repair kits by OPTIMAL. In
cooperation with Paschke Profitec, OPTIMAL engineers
have developed a non-wearing and cost-effective tool
(see photo below), enabling an economical repair to be
carried out.

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2. The advantages

2.1. Advantages of the OPTIMAL repair kit:

 Low-cost vehicle repair
 No need to remove the rear axle
 Low tool costs
 Repair on one side possible (left/right)
 Complete kit in a single pack
 Assembly instructions enclosed with link to repair video
 Assembly can also be performed using other tools
 All components manufactured in comparable OE quality

2.2. Advantages of the OPTIMAL tool:

 No welding is necessary for pulling the stub shaft
 Long pressure pipe, meaning greater distance to the side part and 360° turns possible
 Wear-resistant spindle with standard metric thread saves time thanks to a greater transmission
ratio of strength and rotation angle
 The standard thread means there is no self-locking effect (as is the case with fine threads)
 The spindle has a hexagon allowing it to be countered
 Torsion-proof spindle nuts (driving nut)
 Axial bearing unit encapsulated in pressure piece for greater dirt protection
 A sophisticated stub shaft pulling procedure makes exchanging on one vehicle side possible
 The mechanical tool can be adapted to common hydraulic hollow piston cylinders (less effort
required, huge time saving)

3. The PSA repair kits

Applications OPTIMAL reference Corresponding reference Note

no. no. *
205, 306, 309, Xsara (Picasso), ZX G8-272 965905S Without tool
206 with RA disc brake (Org. 9501→) G8-277 965906S
206 with RA disc brake (→ Org. 9500) G8-248 965911S
206 with RA drum brake G8-197 965913S
Oversize stub
405, Partner, Berlingo, Xsara Picasso G8-276-5017 965912S+965900 shaft
Oversize stub
405, Partner, Berlingo, Xsara Picasso G8-276-5020 965912S+965901 shaft
106, AX, Saxo without stabilizer G8-274 965909S
106, AX, Saxo with stabilizer G8-275 965908S
*Attention please. All foreign and original numbers from automobile manufacturers listed in this table are for
comparison purposes only and may not be used in invoices to car owners.

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4. Assembly instructions

Before assembling step by step, please consider the following information first:

Important note:
The installation may only be carried out by qualified specialists. Please check the availability of
repair kits beforehand, since vehicles can no longer be moved once the rear axle has been
dismantled! The repair or exchange of stub shaft may only be performed once per vehicle side!

4.1. Preliminary work to be carried out on the vehicle:

 Always take the vehicle manufacturer's instructions into consideration

 Separate the mechanical and/or hydraulic connection of the brake to the trailing arms (hand
brake, brake drum etc.)
 Disassemble shock absorbers
 Clean screw connections and toothings of the torsion bars and apply rust solvent
 Disconnect electrical plug connections (e.g. ABS sensors)
 Measure the distance between the highest point of the fender edge and wheel hub center
(reference dimension for the height of the vehicle)

Depending on the execution:

 Remove plastic and retaining screw from the stabilizer plate (left side of vehicle)
 Turn M12x1.5x50 screw into the thread of the plastic screw in order to force the metal plate
away from the stabilizer. Then detach the plate on the other side of the vehicle

Or:

 Unscrew clamping screws from the stabilizer, drive stabilizer out to the right

The next step is to remove the torsion bars:

 Remove screws and eccentric washers in front of the torsion bars and clean the grooves
 Mark the positions of the torsion bars using a prick punch (dimension for installation)
 Drive out torsion bars in the direction of the larger toothing
 Take off the swing arms or trailing arms
 Measure projection of the old stub shaft (reference dimension for new stub shaft)
 Remove coarse rust at the internal diameter of the stub shaft using a file

Please note that the OPTIMAL tool is universally applicable and can be used for all rear axles of these
series. The individual components of the tool are not generally used depending on the vehicle model but
on the inside diameter of the stub shaft to be pulled. Inside diameters of 26 mm, 28 mm and 34 mm are
differentiated between. (Depending on the execution, the inside diameter may vary at the front and back.
The smallest inside diameter shall be applicable.)

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4.2. Removal

We will explain how to exchange the various stub shaft below.

4.2.1. Removal for the inside diameter of 26 millimeters

The two spindles (M20x1000mm = type no. 33819610, M20x740mm with hexagon = type no. 33819609)
are to be screwed with the connection element (33819603) and a graphite spray is to be applied for
lubrication. Then push the shells with spokes (33819501) through the stub shaft one after the other. You
then need to position the first shell in the lower area behind the stub shaft; then successively align the two
other shells. You can use the guide ring to help you, exerting a slight pull on the shells already aligned.
The screwed-on spokes on the shells primarily serve for positioning and are bent 90° at their ends. Once
all three shells are in the correct position, the spokes will each be 120° apart and pointing in different
directions. With the chamfered hexagon in front, push the spindle into the axle tube from the opposite side
of the vehicle. When inserting the spindle, make sure that the shells remain in their position! Then
take a torch and check from the opposite side of the vehicle that the shells are correctly seated. Keep the
spindle with the connection element lightly pressed against the shells in order to prevent the shells from
slipping. You then need to slide the pressure pipe (33819604) and the pressure piece with bearing
(33819605) over the spindle. Now turn the enclosed hexagon nut onto the spindle and then re-check the
correct seating of the shells from the other side of the vehicle.

Now use a ring wrench (with an appropriately sized lever arm) to turn the nut to the right, until the stub
shaft has been completely pulled out of the axle.

4.2.2 Removal for the inside diameter of 28 millimeters

The two spindles (M20x1000mm = type no. 33819610, M20x740mm with hexagon = type no. 33819609)
are to be screwed with the connection element (33819603) and a graphite spray is to be applied for
lubrication. You then slide the conical sleeve (33819602) onto the spindle. The plane side of the conical
sleeve will be touching the connection element. Now push the spindle with conical sleeve from the
opposite side of the vehicle (where there is an stub shaft with a diameter of 34 mm) into the axle tube. You
then need to slide the pressure pipe (33819604) and the pressure piece with bearing (33819605) over the
spindle. Now turn the enclosed hexagon nut onto the spindle. Finally, use a ring wrench (with an
appropriately sized lever arm) to turn the nut to the right, until the stub shaft has been completely pulled
out of the axle.

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4.2.3 Removal for the inside diameter of 34 millimeters

The spindle with hexagon (33819609) is to be screwed with the connection element (33819603) and a
graphite spray is to be applied for lubrication. You then slide the conical sleeve (33819602) onto the
spindle. The plane side of the conical sleeve will be touching the connection element. The shells are now
positioned in front of the conical tip and in doing so, these need to enclose the spindle. For this purpose,
hold the shells on the spindle with one hand and insert the spokes and the guide ring into the stub shaft
using your other hand, along with the spindle with the connection element and the shells.

In order to ensure that the shells are in the correct position and can no longer force each other to the side,
pull the spindle slowly towards you. The cone will then spread the shells apart. Then take a torch and
check from the opposite side of the vehicle that the shells are correctly seated. Now keep the spindle with
the connection element and cone lightly pressed against the shells in order to prevent the shells from
slipping. You then need to slide the pressure pipe (33819604) and the pressure piece with bearing
(33819605) over the spindle. Now turn the enclosed hexagon nut onto the spindle and then re-check the
correct seating of the shells from the other side of the vehicle. Finally, use a ring spanner again (with an
appropriately sized lever arm) to turn the nut to the right, until the stub shaft has been completely pulled
out of the axle.

4.3. Installation

Before pressing in the new stub shaft, clean all contact surfaces in the axle yoke or axle tube and check
that they are in sound condition.

The two spindles (M20x1000mm = type no. 33819610, M20x740mm with hexagon = type no. 33819609)
are to be screwed with the connection element (33819603) and a graphite spray is to be applied for
lubrication. You then need to slide these onto the axle. On the side where the defective stub shaft was
removed, you now need to grease the new stub shaft and position or insert it on the short spindle
(33819609) or into the axle yoke.

Now, on the opposite side of the vehicle, slide the pressure pipe (33819604) over the stub shaft, put on
the pressure piece (33819605) and screw it with the hexagon nut. You then need to pull in the new axle
journal using the pressure piece (33819607) and the hexagon nut. Please make sure that the stub shaft is
pulled in straight, correcting with light knocks of a rubber mallet where necessary.

Important notes:

1. Please note the press-in depth measured beforehand and/or the marking on the stub shaft.
Only turn the hexagon nuts on the side of the tool on which the pressure piece (33819605) with
integrated axial bearing is located!
2. Note: For the Berlingo, Partner, Xsara Picasso and Peugeot 405 types, oversize stub shaft
must be used since there is a small projection at the end of the original journal. This projection
wears away material in the axle yoke, which is why the standard dimension cannot be worked
with. Since this projection varies, Optimal offers two different oversize stub shaft.
3. Oversize stub shaft by OPTIMAL: G8-276-5017 corresponds to a dimension of 50.17mm and
G8-276-5020 corresponds to a dimension of 50.20mm.

Once the old stub shaft has been pulled out, you must measure the axle yoke using an inside caliper. For
this purpose, you should classify the axle yoke into different 3 areas: The front, center and rear. You need
to measure vertically and horizontally in each of these areas. On the basis of these 6 measurements, you
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then need to determine the average and then use the actual value to select the appropriate new stub shaft
from the following table of target values:

G8-276-5017 G8-276-5020
Set value 50,133-50,155 50,155-50,185

Picture

Note: The actual values measured must not go below or exceed the target values!

After pulling in the new stub shaft, you must exchange the bearings, seals and, if necessary, the spacer
sleeves in the stub axle in accordance with manufacturer specifications. The bearings are to be freed from
old bearing remains and corrosion beforehand and checked for damage. Then insert the trailing arms and
torsion bars in the measured (or previously marked) positions. The installation of the shock absorbers,
brake system etc. is then performed in reverse order.

5. Further information

You can also find our assembly instructions online by clicking on the following link:
www.optimal-germany-marketing.de/upload/OP TIMA L_PSA_rear_axle_repair_en. pdf
To assist with PSA rear axle repair we have also made three repair videos that you can watch by clicking
on the following links:
PSA rear axle repair with Bendix repair kits – part one: inside diameter 28 millimeters
https://www.youtube.com/watch?v=y54S9Q50wK4
PSA rear axle repair with Bendix repair kits – part two: inside diameter 34 millimeters
https://www.youtube.com/watch?v=WT-9-cDZqls
PSA rear axle repair with Bendix repair kits – part one: inside diameter 26 millimeters
https://www.youtube.com/watch?v=rvim_60wAPw

OPTIMAL – your profit:

We hope that our assembly instructions and our repair video have been helpful to you.
Subscribe to our newsletter on our website for further technical tips.

On our website you can also find information about our training program!

You can find more details at: www.optimal-germany.com / training@optimal-germany.com

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