DS 19 OPERATION No. DS 331-1 : Replacement of a gearbox cover. Op. DS 331-1 218
TOOLS
c) Insert the 3rd and 4th speed selector shaft (61) and its return spring. Fit the locking plungers (66), the rocker
(63) and the 3rd and 4th speed selector fork (64).
d) Tighten the locking screws on the selector forks. Lock the screws with an iron wire so as to prevent any
rotation in the direction of unscrewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 mm spanner
11 To fit the cover on the gearbox :
a) Make sure that the selector fork shafts and the sliding pinions are in the neutral position.
b) With grease, stick the paper cover joint on the cover. Also stick the 3rd and 4th speed selector fork thrust pads
in position, with grease.
c) Put the cover in position on the gearbox. Make sure that the selector forks are correctly positioned in the groove
of the sliding pinions and that the 1st speed control lever is engaged in the 1st and 2nd speed selector fork.
d) Fix the cover on the gearbox with the two centring screws, then with the other screws and studs.
12 To adjust the 4th speed control cylinder (see Pl. 52):
a) With the help of an assistant, bring the base of the 3rd speed synchro (90) as far as possible into contact with
the thrust washers of the pinion, by pushing the selector shaft (61) and holding the shaft in this position. Put the
rear pipe assembly in position (do not fit the adjusting washers between the 4th speed control cylinder and the
joint face on the gearbox cover.
b) Hold the pipe assembly and, with a set of feeler gauges, measure the clearance (at several points) between the
control cylinder and the gearbox cover, for example : 1.35 mm.
In order to obtain a clearance of 0.1 to 0.3 mm between the face of the synchro and the thrust washer, it is
necessary to fit an adjusting washer with a thickness of between
1.35 – 0.3 = 1.05 mm and 1.35 – 0.1 = 1.25 mm.
c) Select from the adjusting washers sold by our Spare Parts Department, a washer of the appropriate thickness.
In the example: a suitable washer would be 1.1 mm.
13 To adjust the 3rd speed control cylinder :
Proceed as in paragraph 12 above, after having engaged the 4th speed as far as possible (push the shaft (61)
towards the front).
14 To adjust the 1st speed control cylinder (see Pl. 55).
Put the 3rd and 4th speed shaft in the neutral position. Engage the 2nd speed as far as possible by pushing on the
shaft (77). Proceed as mentioned in paragraph 12 above. The clearance obtained between the synchro and the
reverse pinion should be between 0.30 and 0.65 mm.
15 Remove the cover, fitted with the pipe assembly from the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm hex spanner
16 Adjust the clamps fixing the pipe assembly (see Op. DS 334-0) and fit the clamp fixing screws (socket 1773-T,
see Pl. 64, fig. 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Socket 1773-T
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