Peugeot 406 Problems: Common Issues and Repair Costs
The Peugeot 406, produced from 1995 to 2004, is well-known for its elegant design, smooth ride, and strong build quality. Whether you own the saloon, estate, or coupe version, it’s a practical and comfortable vehicle. But like any car of its age, the 406 has its fair share of common faults. This guide outlines the most reported problems and what they typically cost to fix.
1. Suspension and Steering Wear
Suspension components wear out with age, especially if the car has done a lot of miles or lived on rough roads.
Common symptoms:
- Clunking noises when driving over bumps
- Loose or vague steering feel
- Uneven tyre wear
Typical repair costs:
- Anti-roll bar links or lower ball joints: £100 to £300 each
- Complete front suspension refresh: £400 to £800
Regular checks and early replacement of worn parts can help maintain ride quality and handling.
2. Electrical and Sensor Issues
Electrical problems are common on older Peugeots, and the 406 is no exception.
Frequent issues include:
- ABS or airbag warning lights
- Dashboard display failure
- Central locking malfunctions
Repair costs:
- Diagnostic scan: £60 to £150
- Sensor or relay replacement: £100 to £300
- Dashboard module replacement: £200 to £400
Corroded wiring and worn connectors are often the cause, especially in damp UK climates.
3. Power Steering Problems
As the car ages, power steering pumps and fluid hoses can start to fail or leak.
Signs to watch for:
- Heavier than usual steering
- Groaning noises when turning the wheel
- Fluid leaking underneath the car
Repair costs:
- Power steering pump replacement: £300 to £500
- Hose replacement and fluid refill: £150 to £300
Steering issues should be repaired quickly to ensure safe driving.
4. Oil Leaks and Gasket Wear
Oil leaks are fairly common on both petrol and diesel 406 engines, especially around old gaskets and seals.
Typical leak areas:
- Valve cover gasket
- Sump gasket
- Camshaft or crankshaft seals
Repair costs:
- Minor gasket replacement: £150 to £250
- Full gasket reseal or seal replacement: £300 to £400
Fixing leaks early prevents damage to belts, hoses, and other engine parts.
5. Timing Belt and Chain Service
Timing belts and chains are essential components, and failure can lead to major engine damage.
Recommended service:
- Diesel timing belt: every 80,000 to 100,000 miles
- Petrol timing chain: check around 90,000 miles for wear or noise
Repair costs:
- Timing belt and water pump kit: £350 to £600
- Timing chain and tensioner: £400 to £800
- Engine rebuild (if failure occurs): £2,000 to £4,000
Following service intervals is critical to avoiding breakdowns.
6. Turbocharger and Boost Hose Issues
If you own a turbo diesel version of the 406, you may experience issues with turbo components.
Warning signs:
- Loss of engine power
- High-pitched whistling noise
- Black smoke from the exhaust
Repair costs:
- Turbo reconditioning or replacement: £600 to £1,200
- Boost hose replacement: £150 to £300
Turbo issues can quickly lead to limp mode and poor performance.
7. DPF and EGR Valve Problems
Diesel models with a Diesel Particulate Filter (DPF) or Exhaust Gas Recirculation (EGR) valve are known to clog up if driven mainly on short journeys.
Repair costs:
- DPF cleaning or forced regeneration: £200 to £400
- DPF replacement: £600 to £900
- EGR valve replacement: £250 to £450
Frequent motorway driving can help prevent these issues.
8. Clutch Wear and Replacement
High-mileage Peugeot 406s often need clutch replacement, particularly if towing or city driving was common.
Repair costs:
- Clutch replacement (petrol engines): £529 to £681
- Clutch replacement (V6): £606 to £684
If you notice slipping, vibration, or difficulty shifting gears, have the clutch checked.
Summary of Common Repair Costs
| Problem Area | Typical Cost (UK) |
|---|---|
| Anti-roll bar links or ball joints | £100 to £300 per item |
| Suspension overhaul | £400 to £800 |
| Diagnostic scan | £60 to £150 |
| Sensor or module replacement | £100 to £300 |
| Power steering pump or hose | £150 to £500 |
| Gasket or oil seal replacement | £150 to £400 |
| Timing belt and water pump | £350 to £600 |
| Timing chain and tensioner | £400 to £800 |
| Turbocharger reconditioning | £600 to £1,200 |
| Boost pipe replacement | £150 to £300 |
| DPF or EGR servicing | £200 to £900 |
| Clutch replacement | £529 to £684 |
| Engine rebuild (belt failure) | £2,000 to £4,000 |
Tips for Peugeot 406 Owners
- Check suspension regularly to avoid tyre wear and steering problems.
- Scan your car for warning lights before every MOT or major service.
- Stick to timing belt or chain intervals to avoid engine failure.
- Watch for oil leaks and fix them early to prevent engine damage.
- Use a trusted independent garage that understands older Peugeots.
- Keep £500 to £1,000 per year set aside for general repairs and maintenance.
Final Thoughts
The Peugeot 406 is a comfortable and capable car with timeless design, especially in coupe form. While it’s showing its age, the most common problems are known and manageable. With proper care, regular servicing, and preventative maintenance, the 406 can still be a reliable and enjoyable car to own.
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