CITROEN DS 19 - Page 219

DS 19 OPERATION No. DS 331-1 Replacement of a gearbox cover. Op. DS 331-1 217
TOOLS
REMOVAL.
1 Hold the bonnet open (stop MR-4158, see Pl. 16, fig. 1). Remove the spare wheel, the spare wheel support, the
front wings, the air deflection panel and the battery tray. Release the pressure in the hydraulic systems . . . . . . Stop MR-4158
8-12-14 mm spanners
8-12-14 mm box
spanners
2 Drain the radiator, retain the water which contains anti-freeze. Remove the radiator (see Op. DS 232-1).
3 Remove the steering (see Op. DS 100-1, paragraph 10).
4 To remove the front crossmember support :
a) Support the engine-gearbox assembly by means of a sheathed chain sling, passed around the water pump cover
(chain sling and stand 1797-T (or lifting tackle), see Pl. 51) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chain sling 1697-T
Stand 1797-T
b) Remove the clamp fixing the expansion chamber and its support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14 mm box spanners
c) Remove the lower adjusting nuts of the brake unit front support tie-rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 mm spanner
21 mm box spanner
d) Remove the screws fixing the crossmember (lower part) on the gearbox support arms 14 mm box spanner
e) Remove the screws fixing the crossmember (upper part) on the sidemember. Disengage the crossmember,
retain the adjusting shims fitted between the crossmember and the sidemember . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm box spanner
5 Remove the front brake connecting cable.
6 Remove the connecting pipe between the high pressure pump and pressure regulator (spanner 2222-T, see Pl. 71,
fig. 4 or 14 mm spanner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spanner 2222-T or
14 mm spanner
7 Disconnect the pipe assembly (5 pipes) controlling the gears, from the gearbox cover . . . . . . . . . . . . . . . . . . . . . . 8 or 10 mm box
spanners
8 To remove the gearbox cover. Commence by lifting the cover vertically, from the gearbox. Remove the 3rd and
4th speed selector fork thrust pads in order to avoid dropping them downwards. Remove the cover, together
with the control pipe assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm box spanner
9 Dismantle the cover (see Op. DS 330-3, paragraph 20).
ASSEMBLY
10 To fit the selector forks on the gearbox cover (see Pl. 55) :
a) Engage the 1st and 2nd speed shaft (77) through the rear of the cover, fit the return springs without the cups
then fit the selector fork (78) (spring compressor 1798-T, see Pl. 56, fig. 1).
Fit the locking plungers (66) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring compressor
b) Fit the reverse selector shaft (79), its return spring and the selector fork (80) 1798T