DS 19 OPERATION No. DS 330-3 Overhauling a gearbox. Op. DS 3303 198
TOOLS
7 Remove the circlip (16) retaining the rear mainshaft bearing (17) (use circlip pliers). Remove the distance piece
(18), the bearing (17) and the 1st speed pinion (19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circlip pliers
8 Loosen the housing of the front bearing (21) by striking the end of the shaft (22) with a mallet. Extract the assembly
of the bearing and housing by means of small levers (cars produced before October 1957) or extract the
shouldered bearing (21) (extractor body 1750-T, split collet and ring 1738-T, see Pl. 64, fig. 1) (cars
produced after October 1957) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extractor 1750-T
Split collet and ring
1738-T
9 Remove the spindle (23) of the 1st speed selector fork (24) (see Pl. 57) and push the fork towards the rear . . . . . . . . 21 mm box spanner
10 Put the synchromeshes in 2nd and 4th gear positions. Remove the mainshaft assembly and pinions through the top
of the gearbox casing.
11 To remove the reverse gear layshaft (see Pl. 54, fig. 2):
a) Remove the screw (27) locking the spindle (untighten the locknut) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm box spanner
b) Drive out the steel plug (28) closing the hole for the spindle in the front face of the gearbox casing.
c) Draw out the spindle (29) by means of a 7 mm dia. x 100 pitch screw with several threads screwed into the
spindle. Remove the assembly of the reverse gear layshaft and ball thrust race (30), the adjusting shims (31), the
needle bearing assemblies (32) and their distance piece (33).
12 Drive out the bevel pinion (25) by striking the end with a bronze drift. Do not mislay the rollers from the
bearing (26). Remove the bevel pinion (25) from the box.
NOTE - On early models, it is necessary to drive out the bevel pinion before removing the mainshaft.
13 Move the bevel pinion shaft front bearing assembly (35), some millimetres out of the gearbox casing, in order
to remove the pinions comprising the intermediate train and the 1st speed selector fork.
14 With a drift, drive out the front bevel pinion shaft bearing and the outer race of the rear bevel pinion shaft bearing (26).
15 Remove the speedometer pinion, the filler and drain plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 mm box spanner
16 To strip the mainshaft (see Pl. 53, fig. 1)
a) Disengage the 4th speed loose pinion (36), the 2nd speed synchromesh assembly (37).
NOTE - Do not pull the synchromesh by the collar, otherwise the driving pins (38) will escape from the pinion and
will fall out. Do not mislay the synchromesh adjusting shims (39) found between the synchromesh and the
pinion.
b) Disengage the 2nd speed loose pinion (40), the washer (41) retaining the half segments (42), the 3rd speed loose
pinion (43). Remove the needle bearing assemblies from the loose pinions. (Note : these needle bearing
assemblies are not of the same dimensions).
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