How to replace brake rotors (discs) on Peugeot and Citroën cars, all models

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OVERALL DIFFICULTY INDEX: 4/10
IF YOU HAVE NO TOOLS, YOU PAY $50 TO GET THEM FOR THIS JOB
IF YOU HAVE NO EXPERIENCE YOU SPEND 4 HOURS TO CARRY OUT THIS JOB
SAFETY: RISK OF INJURY/DEATH FROM A LIFTED VEHICLE. SEE BELOW FOR PRECAUTIONS.

BEFORE YOU START

It is mandatory to use jack stands. Any intervention nearby or beneath a vehicle that stands on a manual or hydraulic jack MUST be secured with one or more jack stands used on a horizontal surface.
The job is technically simple but requires some force for removing and refitting the wheels.
Wash the car with a water jet machine or at least the wheels prior to this intervention for reducing the level of brake dust.
Below interventions concern the front brake discs of Peugeot 208 and 5008 models but the same applies to all Peugeot and Citroën vehicles.

DISCLAIMER:
Our pictorials are of informative nature and do illustrate works carried out by ourselves at our own premises for our own use and satisfaction.
Readers who envisage to carry out similar works inspired by the below method shall do this at their own risks and liability.

Symptoms of worn brake discs (rotors) and how to test them

Brake rotors are discs made of two parts separated by air with ventilation fins.
They are the surface against which the brake pads are squeezed when you press on your brake pedal.
The resulting friction between the pads which are fix and the discs which rotate with the wheel slows down your vehicle. Heat is generated and both pads and discs erode and loose particles upon each braking, pads getting worn much faster than the discs though.
For this reason, you replace your brake pads three or four times prior to replacing your brake discs.
This applies to absolutely all cars of any make and any type, ICE powered, Electric vehicles, Hybrid vehicles, etc.

Worn brake rotors (discs) will generate the following symptoms:

Whistling noise when braking, especially after fitting new brake pads
Vibrations in the steering wheel, and others of lesser intensity felt in the whole vehicle, when braking on highway at medium and high speeds
On very recent cars of the "steer by wire" (steer-by-wire) technology, vibrations will be felt in the whole vehicle without being amplified by the steering wheel.

For testing the brake discs of your car, simply slide the nail of your index finger on the disc (wait until it's cold!), moving it in a radial direction (like drawing a radius): if it gets stuck at some point, then your discs need replacement.

How to remove the brake discs (rotors)

Remove the wheel.
Do not intervene on the discs unless the vehicle is placed on stands.

You need to remove the brake caliper first.
The caliper is fixed by the means of two bolts. Unscrew them while taking care not to damage the hydraulic brake hose with your tool.
The lower bolt of the caliper is of an easier access. You can easily fit a ratchet handle.

Use a large slotted screwdriver for taking off the caliper.

Gently rotate it and let it hold somewhere on the suspension. of your car.

Take off the brake pads.

Now the caliper support. It is also held by two bolts.
The bolts that hold the brake caliper support require a Torx socket and a ratchet handle, nevertheless more force is required to slacken them due to their high tightening torque.
Take off the caliper support.

Unscrew the two small bolts that hold the brake rotor (disc) to the wheel hub.
The disc could then come out on its own or by gently hitting it with a mallet (plastic hammer).
If the rotor cannot be freed easily, you will need to use an extractor, see bottom of page for using the brake rotor tool.

You are now ready to fit the new brake rotor or disc.

Fitting new brake rotors (discs) on Peugeot and Citroën vehicles

The new brake discs are always greased to avoid corrosion, thus the need to hold them with gloves.
Refit the new rotor on the wheel hub and tighten the disc bolts to a torque of 1.5 mKg.

Put 2 drops of a thread lock on the caliper support bolts., refit them and tighten to a torque of 6 mKg.
Fit new brake pads and push back the caliper piston; for rear brakes, click here to see how to push back the brake piston.
Use the new bolts supplied with the pads, add one drop of lock thread and refit the brake caliper.
Refit the wheel and remove your jack stands.

Before driving !

1- Turn on the engine WITHOUT DRIVING THE VEHICLE, i.e. while the parking brake is still applied.
2- Press the brake pedal several times until it becomes stiff as usual. Do not continue to "pump".
3- Drive and test gently the brakes. Avoid strong braking during the first 100Km after pad replacement.

Using a 3-arm puller to pull out the brake disc (rotor):

Here's what to do when the brake discs cannot be taken out by hand: