1966 404 Coupé Injection Restoration

3 minute(s) of a 255 minute read

On the right, new old stock front suspension arms with new bushings, painted in POR-15.

On the left, the two arms that came out of the 404C.  One had a totally loose bushing that fell out when the arm was removed (I drove the metal sleeve out with a chisel).  That one is in good condition and I will repaint it for future spare parts.  The one with the bushing still in it has damaged threading and will be recycled.

Yes, the big threads stripped on the left arm.  I had to apply about 1400 Nm of force to get that one off.  Even after unstaking the nut, it was super tight.  This is a weak point in the 404, if the threads start to strip, the suspension geometry changes and eventually the threads can let go entirely.  I had bad threads on a 404C before and it took a while for me to realize what was loose when the steering got weird in a corner.  That is why I decided to use brand new front arms in this case, which should be good for the next 50 years if not more.

It is the thread visible at the end of the arm.  I applied the estimated torque with a ~90 cm long breaker bar, holding the far end and using all my body weight 100+kg) and more to break the nut free.  I had to use the breaker bar for about 10 turns of the nut, that is how bad it was!

1-13-2017

Tonight I was sanding rust off the anti-roll bar components and a few other small bits.  Fiddly work and most unpleasant....Friday night or Sunday I will paint them with POR-15 as well.  I hope to finish cleaning the rear axle casing as well.  Then I need to sandblast the cast iron crossmember, brake drums (outer surfaces), brake backing plates, Panhard rod, rear springs and some other bits and paint them as well.  At that point the suspension cleaning and painting will be complete and bushings will need to be pressed in and it'll be ready.

Meanwhile I hope on Saturday to have the new front (Peugeot OE)  shocks installed.

And then I have to start work on all the other parts: wipers, heater motor, door innards including window mechanisms, other bits and pieces.

The gearbox needs new bearings so I will have someone in Victoria do that job, and the engine needs a rebuild.  I will do that myself but lots of contracting out is needed.  The new head needs unleaded valve seats, crank may need a grind, engine block needs to be boiled out and painted, and so on.

Fuel tank needs to be cleaned out and sealed, radiator and heater core need work.

It has been good.  The suspension part preparation has consisted of sanding with 80 grit paper and then wire brushing by hand with rust remover, washing, drying the cleaning with solvent.  So the surface is very rough.  It's brushed on and the surface is perfectly smooth after drying.  Adherence so far is amazing.

Agreed about powder coat, one nick and it comes off in huge flakes a year later.