What did you do today to your Pug

[504gld]

The mechanisum looks fairly simple for the windows, had my door to pieces when I mended a hole in the bottom.

Two things, to get the window winder handle off you need to remove a spring clip, and trust me its springy! Haynes says use a piece of wire with a hooked end, this works to some extent.

The window runners rust, and are made from thin tin looking metal. I have given the whole of the inside of the door a good waxoyling including the runners.

Its worth making sure the drain holes are clear when you have door to pieces as well, and even tipping water in the bottom to make sure. Sounds silly but the drain hole may not be at the lowest point, if it doesn't fully drain drill a new one and rust protect it!

Mat.

[Alfasudcrazy]

Today - availing of brilliant sunshine I tackled the job of fixing the drivers window of my 504 which had become derailed from its runners.
Thanks for the warning about that clip for the window winder GLD – it would have been a mystery otherwise as this clip is practically invisible at first glance.
Following the instructions of my 504 manual I made this hook from a small clip and pointed it gently with my angle grinder. The vice grip made it a really useful tool.



I then had no problem taking out the clip but you have to be careful the clip does not fly away into oblivion.




Then I removed the other bits



When I removed the door card my first sight was this



I had not much difficulty getting the window back into its runners but the cause of its derailment was not discovered as all runners are tightly fixed and are not rusty and it refused to become derailed again even after repeated testing.

The chrome strip that runs along the base of the drivers window also fell of (luckily I was stopped in traffic at the time and saw it happen so I was able to recover it undamaged).
But it did reveal slight rusting occurring at the top of the door panel. I got all this off with the help of a flat screwdriver and sandpaper and put my rust treatment on it.
I then managed to get some touch up paint from my local motor factors which I carefully hand painted on and allowed to dry.
Thankfully the obviously fastidious previous owner to whom this car is a credit wrote down the paint code in the car’s handbook.
The paint is actually called ‘Rouge Aramante’



Here is it painted and ready to refit the chrome strip.



and finally the finished job ;D



I have not replaced the door card yet as I want to treat the rust at the base of the door. It is only internal as the exterior is fine – I am open to suggestions as to how best to do this.

[504gld]

You have been busy, great to see the series of photos as well. Looks just like the inside of my doors too, hence my suggestion of extra drainage hole! My however are much worse with holes in the bottoms. I scraped off as much rust as I could, and used a small wire brush (bit bigger than a tooth brush) to do the inside. Used a vacuum cleaner to suck out all the dust and muck. I used Locktite Rust Eater, and painted on several coats as per instructions, then hammerited inside and out. In the bottom of my door apart from the hole which I filled using fibreglass filler kit, the door skin had come away from the bottom of the frame.

My biggest challenge will be doing the rear drivers side door, as its been eaten away I could put my hand through it. I would like a set of new doors and am surfing the net. Half tempted to see how much a new set is in Kenya and ship them over from Marshalls.

The paint code should be under the bonnet on the inner wing near the battery. A letter and numbers. Mine is Gazelle (thats beige to you and me!).

[504gld]

Spent the morning, doing the valve clearances. Shouldn't of taken long, but it did. Why? silly arse me forgot to bolt the earth cable back on to the bulk head for the glow plug relay...so it didn't start......
(pics in new thred).

[504gld]

Bit of an update before the thred dies!

Got the wheel wobble on the 504 sorted now, phew it was driving me mad! A new wheel bearing sorted out a slight squeek and a small bit of wobble but didn't cure it all together.

Sourced a new steering rack from Quentin Hazell and hey presto, drives like new. It wasn't without its hasstles though, as QH ones don't come with the passenger side eyelet bush. Sourced one to fit (309 in fact), got that pushed in with a bit of a struggle. On the other end, the track rod end was not going to unscrew - its like a hollow rod thredded though for the track rod end to screw into one end, and the rack the other. Had to get it red hot to unscrew it.

Get it all assembled and side it back under the car, and then find, the eyelet end isn't in line, so out it comes again, and adjust that end. Back on the car, and connected up. Damm, steering wheel now upside down!, off with the coupling, turn round and back ok-ish.

Drove ok, like new I suppose! In to Kwik-fit for a tracking adjustment, thought it would be a "no mate cant do those", instead greated by "I had one of those, a Ti, then a 604Ti"...... Fantastic job done, thank you Kwik Fit Devizes.

The steering now is very solid feeling, not over heavy but there is a tiny tiny feeling of vibration at about 55mph, but thats more like worn engine mounting rubbers I think. At 70, (yes it goes a bit faster!), perfect no movement, no pull !

Taken a while out now for the underside to dry, been at it with the jet washer, ready to Waxoyl the floor pans and seals.

Me I'm covered head to toe in muck now and need a jet wash myself!

[Alfasudcrazy]

Good work GLD - wish I had the expertise to work on my 504 like that -
just one question - I want to change the passenger (LHS) side headlamp on my 504. Its not broken/rusty or anything its just that the backing on it is done in a kind of dark brass colour while the one at the drivers side is bright silver. It gives the front of the car a 'black eye' look which i don't like.
What's the best place to source a silver backed headlamp?

[504gld]

Hi, these shouldn't be a problem at all. The question is how much do you want to pay? The lights should be exactly the same as the pickup truck so you might find a local Peugeot dealer will have them on the shelf. Electric/mechanical dealers like Lucas (LSUK), will be able to get them I expect.

Dean will have them of course, www.peugeotparts.co.uk

You could just go down the scrap yard, most these days have cleaned parts already taken off, or will remove it for you for a couple of quid extra. There are plenty of 504 pickups in the yards!

There were some on ebay the other day!

I will keep an eye open for you, which side is it you want?

[Alfasudcrazy]

One for the passenger side GLD thanks

This pic kinds shows what I mean

[504gld]

I see what you mean. But.. I have just had an email from a guy in London saying he has a 504 and lots of new stock from a project that never got started. I left a worldwide advert for new doors on ebay usa, in the hope a nice rust free Californian pair would show up. He says he has some pannels which I would be interested in and new lights! Will let you know prices when he gets back to me. Mat.

[504gld]

Well the weekend is planned - both track rod ends this time, I'm determined to get rid of this final bit of wobble. The new rack had done a good job so far, but I won a complete new rod with its tracking adjustor on ebay and bought the other side from Dean. They seem very stiff compaired to the original ones so I hope it sorts it. Also got a new steering coupling disc as the current one had a couple of cracks starting to develope. Don't want to loose steering one day, that could be a bit frightening! Advise everybody to check their coupling for perishing. Hopefully the drive to Leicestershire in 2 weeks time will be very enjoyable now.

[504gld]

Hurrah ! no more wobble, smooth as new to drive now. It wasn't without its problems though, the changing of the track rods was a doddle. The steering coupling was supposed to be too, but for whatever reason two of the bolts (which I'd only done up a week ago wouldn't shift). Had to take the whole bloomin steering rack out again and take the grinder to them. This may explain why you get a complete set of nuts and bolts with the new joint. Silly mistake though has cost me a rubber gaiter on the rack though :-( managed to make a hole in it. Will pop another on in a day or two, black tape for the time being, as its only very small.

Final thing was getting the front wheel balancing verified at Peugeot Express Fit in Devizes, seems the only place to have a wheel balancing machine to take non centre holed wheels. The mechanic said, is it a 305? Hmph. No! Oh dear....
The 60 mile journey back from Devizes to Bournemouth was bliss!

Next.... the sump gasket....

[205GRD]

I gave my car a wash today, which was very much needed. The amount of ingrained dirt still on it reminds me that i should wash it more often in future. Found some inseresting?! rust patches that i didnt know about. Looks like fun with some anti rust stuff coming up soon.

[504gld]

Its been an overcast afternoon in Bournemouth, but it didn't stop me taking the 504 for a run down to the seafront for Classic Cars on the Prom. There was a gathering of around 50 classics today, from Alfa GTV, Mini, Morris Minor, Fiat 500, Rolls Royce, Stags, MGs, Cortinas, Capris, Beetles/Campers, Dolimites, etc and of course my 504 which was getting the eye over from a few people too. Do come down to Bournemouth on any Sunday and join in with your pre Aug 83 classic. You need to get there between 4 and 430pm to get a space it fills quickly.

[504gld]

A run from Bournemouth to Andrews at Cirencester for a CPUK meeting, on the way home I though the exhaust had started coming loose and clonking against the body. Once in Devizes at my parent, had a look, no couldn't find any fault in the exhaust. More strange noises started, clonks vibrations and £££ signs! Got the rear wheels up on axle stands and examined the rear drive, all ok. Maybe gearbox? Clutch? didn't fancy getting the engine out for a clutch...then what did I spot? I had lost a bolt from the torque tube which houses the prop shaft!!! Not only lost one, but the other 3 were loose too. It wasn't ever going to drop off but the looseness allowed the shunting of the engine and gearbox on its mounts to clunk and vibrate! they are difficult to access at the top, and they use a allen key to tighten. All fixed now, so off to change the engine and tranny and air cleaner oil.

[205GRD]

I finally got round to sorting out my car ready again for its MOT test over the last few days, new discs and pads, and discovered that the problem with the brakes was a siezed caliper. Finished sorting it yesterday, and dropped it round to the garage for the welding to be sorted this morning. Hopefully itll be back on the road by next week