Complete set of gearbox repair tools
3 videos at bottom of the page
Gearbox overhaul and repair service now available, please see details below.
There's everything needed here to completely overhaul a gearbox for a 602 or 435
There are bearing pullers for all bearings and bearing pushers. I have made the pushers because I don't like hitting bearings into aluminium with tube drifts.
Circlip pliers , clamps, guides for inserting the 3 synchro rings and a guide for the bevel gear bearing circlip.
The bevel gear has to be in a designated position and this size is stamped into its face with another reference to when it was made as a matching set with the crown wheel. These items must not be interchanged with different ones. They are made as mates and cannot be separated.
There are different measuring devices, One, to set and check the bevel gear position and adjust it if necessary with a spacer. Another checks the depth of the crown wheel bearings to calculate how many shims of different thickness have to be added in order to achieve the correct meshing of the differential gearing. You can check the crownwheel to ensure that it is running true.
There are about 40 tools in the set. It is not for sale, but may be hired or any combination of tools can be put together for you to complete a repair.
Gearbox set up of the pinion and the crownwheel. This setting is etched onto the face of the pinion gear. It is crucial that the gear is set to its correct position. This depth setting is the first thing to do and has to be done correctly, no guessing here. If it is not done right, then its a pointless exercise.
Once the crownwheel is held in a temporary position with 2 clamps, and 1 hub and gaskets fastened into position, you can then measure the depth of the other hub casting and the depth of the bearing shell from the face to which it will fasten to. With this measurement, you can establish the total amount of shims required to position the bearings and crownwheel. You must now set the correct position of the crownwheel establishing the correct amount of backlash between the gear teeth. If the pinion is not in its correct position, then you cannot set the backlash properly. Special measuring tools are needed to perform this part of the set up. The final setting will be preloading of the differential bearings. Whenever you change the bearings on the pinion shaft, driven shaft, the output hubs and the differential you will need to recheck all the running clearances. Bearings differ in size and width. It's not much, but it is a fact. So different shims are required for the differential set up and the thrust needle bearing may need a different size of thrust ring, the pinion positioning distance piece will always need to be resized. When I overhaul a gearbox, I change every rotating bearing, so everything must be checked and rechecked. Doing a small repair will not guarantee a long lasting gearbox as most other bearings etc etc will be worn too. It's a costly job to do but you will know that you have a gearbox that is as good as it was when it was new. The video will show you how to do this.
A quick video showing still photos of a rebuild
Gearbox repair and overhaul service.
I have made and created and updated several tools that Citroen used in the 1960's gearbox repair manual. A vast improvement to a, now complete, full kit of repair tools to totally renovate this item. We are now in the year 2019 and things needed to be brought up to date.
A complete overhaul is the only way to ensure that the gearbox will be entirely serviceable for many years to come. A simple repair or component replacement does not guarantee this.
All bearings,oil seals, needle races, thrust needle races, synchro rings, shims etc will be replaced with top quality components.The sliding pinion for 1st/reverse gear can unscrew itself and cause a total disaster. This item will be properly secured within itself. Any damage etc found upon inspection will be reported to the owner. The bevel gear will be set to the factory dimension as well as the meshing of the crownwheel to it. Crownwheel bearings will be preloaded. A completed gearbox, on return to the owner, will not have any oil in it.
The gearbox must be delivered to my workshop and must be picked up at the same.
Turn around time can vary. Parts need to be ordered or made, but generally, 2 weeks should see it completed.
Please enquire and we can have a talk about repairing your gearbox. Pricing is available but a final quote cannot be estimated until and after stripping and inspecting.
You can, of course, hire any tools from the kit to complete your own repairs or even the whole kit. There are fourty odd tools in the set. The kit is not for sale.
Sorry, but I cannot make a repair in the field, so do not offer a travelling service.