DS 19 OPERATION No. DS 330-3 : Overhauling a gearbox. Op. DS 330-3 196
28 To prepare the mainshaft.
Note the descriptions given in the text. There are different types of assemblies.
(a) Clearance of the third-speed pinion locking segments 0.02 to 0.06 mm.
(c) Movement of the synchro bush 0.20 to 0.65 mm.
(d ) Clearance of the rear bearing circlip = 0.02 to 0.06 mm.
(e and f) Clearance between the front bearing and the thrust face on the cap = 0.
29 To prepare the bevel pinion shaft.
(c) Clearance between the front bearing and the thrust face of the cap = 0.
32 To assemble the reverse gear layshaft.
The ground face of the thrust bearing, against the pinion. Lateral clearance of the assembly 0.05 to 0.20 mm.
Make sure that the screw, fitted with hermetic, is in the shaft (at the front).
33 To assemble the bevel pinion.
On cars produced before October 1957, it is necessary to fit the mainshaft before fitting the bevel pinion. Fit an adjusting shim of any
thickness, then the front bearing and the nut.
34 To assemble the mainshaft.
Tighten the starting handle dog to 72 to 87 ft/lb (10 to 12 m.kg). Tighten the bevel pinion shaft nut to 144 ft/lb (20 m.kg) (do not fit a nut with
a small collar).
36 To adjust the bevel pinion shaft.
The dimension which should be obtained at the end of the adjustment, between the centre-line of the differential and the rear face of the bevel
pinion, is engraved on this face, this will vary with each crown wheel and pinion.
Use the adjusting fixture 2044- T.
38 To adjust the engagement of the gears.
Measure the dimension c (see Pl. 55, fig. 7) and select an adjusting washer of a thickness equal to this dimension, reduce the value of
between 0.10 and 0.30 mm for the cylinder controlling the 3rd and 4th speed or the value of between 0.30 and 0.65 mm, for the cylinder
controlling the 1st speed.
42 To adjust the mainshaft rear sealing joint.
The distance to be obtained after assembly, between the adjusting washer and the joint face on the hub of the support block is 16.2 ± 1 mm.
43 To fit and adjust the differential.
Adjust the clearance of the bearings using the support 1766-T and the clearance between the teeth using the fixture 2039-T.
In order to reduce the clearance between the teeth by 0.1 mm it is necessary to increase the thickness of the adjusting washers of the right-
hand differential housing by 0.2 mm.
Clearance between teeth 0.19 to 0.24 mm.
44 On assembly of the differential shaft and housing assemblies, again check the clearance between the teeth.
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