DS 19 OPERATION No. DS 330-1 : Work on the gearbox. Op. DS 330-1 186
TOOLS
Disconnect the steering levers from the relay.
Hold the steering column (setting gauge 1993-T, see Pl. 125).
Disconnect the steering feed pipe assembly (5), from the pinion housing. Remove the bearing caps and remove
the steering. Seal the steering pipe assembly with a plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 mm spanners
8-12 mm box spanners
14-16 mm box spanners
10 mm ring spanner
8 Unscrew the swivel union nut of the high pressure pump (spanner 2280-T, see Pl. 72, fig. 5) and the nut of the Setting gauge 1993-T
high pressure pump tie-rod.
Remove the belts. Remove the pressure control valve (spanner 2220-T, see Pl. 72, fig. 4 or 14 mm spanner).
Seal the return pipe to the reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14 mm box spanners
Spanner 2280-T
Spanner 2220-T or
14 mm spanner
9 Disconnect the wires to the dynamo from the regulator. Disconnect the tie-rod. Untighten the front screw. Remove
the rear screw. Remove the two belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10-12mm box
Spanners
14 mm spanner
10 Remove the driving pulley (109) (do not mislay the key and the adjusting washer). Hold the shaft in position using 14 mm ring spanner
a clamp held by the pulley fixing screw, in order to avoid the shaft being pulled through the ball-race when
removing the gearbox (see Pl. 50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm box spanner
11 Disconnect the 5 pipe assembly from the gearbox. Disconnect the speedometer cable 10 mm ring spanner
12 Disconnect the clutch cylinder feed pipe (spanner 2219-T or 2221-T, see Pl. 72, fig. 4).
Disconnect : the brake feed pipe from the 3-way union (41) (see Pl. 25), the union (111) of the accelerated idling
control pipe, from its fixing plate on the rear brake unit support and the brake feed pipe union (112). Pass the
feed pipe over the idling pipe (see Pl. 141) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spanner 2219-T or
2221-T
13 Disconnect the accelerator control from the carburettor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 mm box spanner
14 Remove the wheels. Disconnect the flexible coupling (bibax) from the gearbox driving plate . . . . . . . . . . . . . . . 12 mm socket extension
15 Disconnect the mechanical brake control. Press on the right-hand brake control lever (3) and unhook the control
cable of the left-hand lever (9) (see Pl. 153).
16 Pass a rubber sheathed chain sling (chain sling 1697-T, see Pl. 51) under the water pump. Support the engine
(engine stand 1797-T, see Pl. 51).
Remove the front engine support crossmember (do not mislay the shims fitted between the crossmember and
the sidemember).
Raise the engine gearbox assembly so that the gearbox will clear the front crossmember. (Note : do not damage Chain sling 1697-T
the accelerator controls) Supportfixture1797~T
14 mm box spanner
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