404 Overhaul
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Thread: 404 Overhaul

  1. #1
    Fellow Frogger!
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    Default 404 Overhaul

    Hi I bought this 404 about 3 weeks ago for $371.00 and have dismantled it to to see exactly what I have
    which is a bit rustier than I hoped so let the welding begin I will tackle the worst rust spots under the windscreen and right side chassis rail under the radiator first and then decide on the floor pan which is border line ,the panels are ok apart from left rear door.
    Mechanically is unknown it has sat in a shed for 4 years with out moving I hope to start it this week before the engine is pulled out. Any suggestions on starting up I will change oil and water.

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    Attached Thumbnails Attached Thumbnails 404 Overhaul-img_0312.jpg   404 Overhaul-img_0313.jpg   404 Overhaul-img_0314.jpg  

  2. #2
    VIP Sponsor 59 Floride's Avatar
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    If It's only been parked for 4 years the donk is probably still ok.

    I have started motors after 10 years being idle no worries.

    You will no doubt take the spark plugs out and do a trial turnover to see what happens before gassing it up. Have a look down the plug holes to see if there is any piston crown damage.

    Take the tappet cover off and see if oit has been pumped up to the top end.

    The carbie will need a clean and blow out and the dizzy will need a clean as well.

    If all is well go for it.

    Nice car BTW.

  3. #3
    1000+ Posts 504-504-504's Avatar
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    Great find and good value.
    Bit of work ahead but that colour is great, hope paintwork buffs up ok.
    Really enjoyed my time with a 404. It was the drum front brake model same as yours.

    Paul

    “A straight is merely the distance between two corners.”

    Current: Peugeot 205 GTi Mi16 1987
    Peugeot 205 Si, one red one silver, both 1991.
    Peugeot 504 Wagon, V6 and 5 speed gearbox.
    Isuzu (Holden) Rodeo, 4WD dual cab, extended chassis.
    Past: Goliath, Isuzu Bellett, Austin A30, Peugeot 203, 403, 404, 504,505.
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  4. #4
    Fellow Frogger! DjB8V's Avatar
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    I love the older 4 door Peugeots.

    Big project man, nice work.



    Chris


    205GTI - 8 valve, single cam coolness.



  5. #5
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    There's a lot of good metal left in that car, and we've all seen worse.

    Maybe not so big a job ahead.

    All the best

    P
    Daily Drivers: R10, R12, R17T(?) Decouvrable

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    R8 (1.4 motor, 4 shock rear end), Dauphine, Pugeot 404

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  6. #6
    Budding Architect ???? pugrambo's Avatar
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    Quote Originally Posted by marty 404 View Post
    Hi I bought this 404 about 3 weeks ago for $371.00 and have dismantled it to to see exactly what I have
    which is a bit rustier than I hoped so let the welding begin I will tackle the worst rust spots under the windscreen and right side chassis rail under the radiator first and then decide on the floor pan which is border line ,the panels are ok apart from left rear door.
    Mechanically is unknown it has sat in a shed for 4 years with out moving I hope to start it this week before the engine is pulled out. Any suggestions on starting up I will change oil and water.
    have you pulled the rear bar off yet ??

    might be a good idea

    otherwise it doesn't look too bad, for a 404
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  7. #7
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    Default 404 overhaul

    I have not pulled the rear bumper is this a common rust area ?,the rear of the car seams a lot better than the front.
    Does anyone know the purpose of the rectangle shaped rubber blocks at the junction between the tail shaft and gearbox.

  8. #8
    Budding Architect ???? pugrambo's Avatar
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    Quote Originally Posted by marty 404 View Post
    I have not pulled the rear bumper is this a common rust area ?,the rear of the car seams a lot better than the front.
    Does anyone know the purpose of the rectangle shaped rubber blocks at the junction between the tail shaft and gearbox.
    the blocks reduce vibration

    the extra chrome strip under the rear bumper looks great, holds dirt/water and hides the inevitable rust from said dirt/water
    3 x '78 604 SL

    1 x '98 306 GTi6

    1 x secret project

    1 x '98 406 STDT troop carrier and i don't care if it stinks, i don't sniff it's arse Death by wank tank

    1 x '99 406SV 5spd wagon, time to burn more fuel

    1 x 1994 605 SV3.0


    WTD long range fuel tank for 605

  9. #9
    1000+ Posts Wildebeest's Avatar
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    Marty,
    I believe the rubber blocks are for transmission vibration damping?
    Check around the rear jacking points for rust. Also if or when the front X member is removed rust may be seen.

  10. #10
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    Default 404 Overhaul

    Hi I have continued to dismantle the green 404 the engine is out and the front end is out ,I will rebuild the front end and refit it once the rust is fixed .The chassis rails are quite bad where it bolts on also a cross member that should be under the radiator curved panel is missing altogether I have no idea what this looks like.
    Goods news is I have been able to run and compression test the engine it sounds and runs very smoothly with no sign of smoke or over heating, the compression is 164,173,162,162, which is better than it was at 25000 miles according to the log books.
    Attached Thumbnails Attached Thumbnails 404 Overhaul-img_0326.jpg   404 Overhaul-img_0327.jpg   404 Overhaul-img_0328.jpg  

  11. #11
    Fellow Frogger! PCOATES505's Avatar
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    Default cross member

    404 Overhaul-404-resto-021.jpg

    404 Overhaul-404-resto-022.jpg

    Before and after

    cheers Pete

    I am gunna get another 403 on the road........one day

  12. #12
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    Marty, when I did my 404 a few years ago that front cross member was RS as they all are. I cut most of it out and found that a bit of 2" gal. steel fence post slotted in nicely. I cut it length and both welded and bolted it to the chassis rail. Super strong and a good place to jack the car up with or mount a sumpguard to. It sailed through a NSW blue slip inspection [painted black with bitumen paint like the rest of the bottom of the car]

  13. #13
    1000+ Posts robmac's Avatar
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    Quote Originally Posted by PCOATES505 View Post
    Click image for larger version. 

Name:	404 resto 021.jpg 
Views:	509 
Size:	99.5 KB 
ID:	26936

    Click image for larger version. 

Name:	404 resto 022.jpg 
Views:	861 
Size:	98.7 KB 
ID:	26937

    Before and after

    cheers Pete
    EAI used to have replacement cross members available. It's a pig odf a job to get the old one off.

    They were about $130 which is than the time spent to make something.

    Peter, looks like you got a replacement.

  14. #14
    Fellow Frogger! PCOATES505's Avatar
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    Default correct

    Quote Originally Posted by robmac View Post
    EAI used to have replacement cross members available. It's a pig odf a job to get the old one off.

    They were about $130 which is than the time spent to make something.

    Peter, looks like you got a replacement.
    Crossmember came with the car, but was bought from EAI

    cheers Pete

    I am gunna get another 403 on the road........one day

  15. #15
    Fellow Frogger! stew's Avatar
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    Good on you! Are you going to keep it that beaut green? I fine motor car in the making.

  16. #16
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    Default 404 fron crossmember

    Quote Originally Posted by PCOATES505 View Post
    Crossmember came with the car, but was bought from EAI

    cheers Pete
    Pug 404 front crossmember panel are currenlty available from Der Franzose in Germany.

    See following web address:

    http://www.franzose.de/en/Peugeot/404/Chassis/ANR77108/

    Cost is 62.90 Euro plus freight and the part is in stock at present according to the website.

    I have ordered various parts (but not a front crossmember) a number of times from this company and all goods I have ordered have arrived albeit slowly (~ 6 weeks: they use DHL sea freight.

    Cheers

    John T

  17. #17
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    John.....50mm square gal fence post in garage....cost nothing.....delivery free and quick!.....and it is much stronger than the original.404 now sold...back in a 504 or the last 3 years. Neil

  18. #18
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    Default 404 Overhaul

    Thanks for pictures and advice I at least know what it should look like I will see if AEI still have them if not I will fabricate something.
    The car will be repainted in the original tannen green I think these cars look good in darker colours with good chrome.

  19. #19
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    Marty, PM me your email address and I will send you some photos of how to do it. Neil

  20. #20
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    Default Marty 404

    Hi I have removed rear bumper and parts ,you guys where not kidding about the rust hiding there unfortunately. I had to cut the whole rear panel off and fabricate new parts then weld them on. I made the lower section from 1.6mm steel to make it strong for the tow bar the top is .8mm steel.
    This is the end of surprises I hope.
    Attached Thumbnails Attached Thumbnails 404 Overhaul-img_0356.jpg   404 Overhaul-img_0359.jpg  

  21. #21
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    Quote Originally Posted by marty 404 View Post
    Hi I have removed rear bumper and parts ,you guys where not kidding about the rust hiding there unfortunately. I had to cut the whole rear panel off and fabricate new parts then weld them on. I made the lower section from 1.6mm steel to make it strong for the tow bar the top is .8mm steel.
    This is the end of surprises I hope.
    Barry Stennert at Toowoomba has about three of those real panels in stock (brand new). I purchased one from him a month of so ago and I think I paid about $90 for it. He has a stack of stuff for old Pugs, alot of it has never been used. Regards Graham

  22. #22
    sans witticism SLC206's Avatar
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    Can I just say, it's so nice to see one that is not white.

    Not that white is a bad colour for them, it's just so common.
    Regards,

    Simon

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  23. #23
    Fellow Frogger! stew's Avatar
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    Keep going Marty. When you're ready for some mechanical help and thinkin', let me know, friend.
    May the goodness that is a 404 bring health and Happiness to your family!
    In other words, keep up the good work, old chap!

  24. #24
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    Default 404 Overhaul

    Thanks for the words of encouragement and Stews offer of mechanical help. I spent the day cutting the steel plates out that the front suspension bolts to, work permitting I will weld in new ones this week and some other sections in the front I had pressed up. The car at some stage has had a big hit to the front right corner that has been badly repaired it must have been close to a right off ! .

  25. #25
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    Default 404 Overhaul

    Hi the welding continues I have finished the left side chassis rail and cut out the damaged right side made pattens and cut some plate.
    My 404 has unassisted drum brakes are these any good do they inspire confidence. What is required to convert to power assisted disks can I keep the 3 stud wheels.
    Another question is will a 2LT 504 carby engine bolt straight in and are good ones easy to find.
    Marty.

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