Page 481
FAULT INVESTIGATION
KEY
Preliminary Adjustment Faults
A.
B.
C.
D.
E.
F.
Fluid level incorrect.
Downshaft valve cable incorrectly assembled or
adjusted.
Manual linkage incorrectly assembled or adjusted.
Incorrect engine idling speed.
Incorrect front band adjustment.
Incorrect rear band adjustment.
Hydraulic Control Faults
a.
b.
c.
.,,
d.
e.
f.
g.
h.
I.
m.
n.
p.
q.
Oil tubes missing or not installed correctly.
Sealing rings missing or broken.
Valve body assembly screws missing or not correctly
tightened.
Primary regulator valve sticking.
Secondary regulator valve sticking.
Throttle valve sticking.
Modulator valve sticking.
Governor valve sticking, leaking or incorrectly
installed.
Orifice control valve sticking.
1-2 shift valve sticking.
2-3 shift valve sticking.
2-3 shift valve plunger sticking.
Converter "out" check valve missing or sticking.
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11111
NN.
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Mechanical Faults
N.
0.
P.
0.
R.
s.
T.
u.
V.
w.
X.
z.
Front clutch slipping due to worn plates, faulty parts
or leaking cup plug in driven shaft.
Front clutch seized or plates distorted.
Rear clutch slipping due to worn plates or faulty
check valve in piston.
Rear clutch seized or plates distorted.
Front band slipping due to faulty servo, broken or
worn band.
Rear band slipping due to faulty servo, broken or
worn band.
One-way clutch slipping or incorrectly installed.
One-way clutch seized.
Input shaft broken.
Pump drive tangs on coverter hub broken.
Pump worn.
Converter blading and/or one-way clutch failed,
stator support fractured .
•
SAAB
440-27
Page 483
REMOVAL AND INSTALLATION
6.
Automatic transmission
REMOVAL
For major work on the engine and transmission, the entire power plant should be lifted out. Removal of the engine by itself is not recommended.
6.
1.
7.
2.
3.
4.
4.
5.
5.
Remove the hood as follows:
Back off both the hood fastening screws. Lift off
the hood. For this you need a helper to hold one
side of the hood and help to lift it clear.
Detach the battery cables. Unclamp and lift out
the battery.
Drain the coolant through the radiator and engine
block drain cocks (later versions: drain plug in engine block).
Carbureted engine:
Detach the vacuum hose of the servo cylinder from
the inlet manifold and pull the fuel hose off the suction side of the fuel pump.
Injection engine:
a. Detach the vacuum hose of the servo cylinder
from the inlet manifold and remove the rubber
bellows between the air flow sensor and inlet
manifold.
b. Thoroughly clean the areas ar11und the fuel line
connections on the fuel distributor and detach
the lines. Plug the holes and blank off the fuel
line ends in a suitable manner.
c. Disconnect the electrical connection on the air
flow sensor.
d. Undo the clamps on the air cleaner and remove
the air cleaner and mixture control unit.
Carbureted engine:
Undo the cable connections to the ignition coil,
temperature transmitter, oil pressure transmitter,
radiator fan, thermostat contact, headlights, headlight wipers and the switch on the gear box.
Injection engine:
a. Undo the cable connections to the ignition coil,
temperature transmitter, radiator fan, thermostat contact, headlights, headlight wiper motor
and the switch on the gear box.
b. Disconnect the cables of the injection system at
the warm-up regulator, auxiliary air valve, cold
start valve and thermo-time switch.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
CAUTION
Do not detach the connections by pulling the cables.
Grip the connecting pieces.
SAM3
Carbureted engine:
a. Remove the air cleaner, the inlet hose and the
preheater complete with hose.
b. Detach the throttle control wire from driver and
bracket.
c. Detach the choke control wire and sheath from
the carburetor.
Injection engine:
Detach the throttle control wire from driver and
bracket on the throttle valve housing.
Detach the hoses at the connections to the thermostat housing, radiator, inlet manifold and water
pump.
a. Remove the grille.
b. Remove the hood lock operating cable from its
fastenings at the dash panel and wheel housing.
c. Remove the two front sheet retaining screws and
nuts, and the four screws holding the headlights
to the body.
d. Remove the front sheet, lifting forward and upward.
Remove the protective cover from the exhaust manifold.
Disconnect the exhaust pipe from the exhaust manifold.mm
~:❖:❖:•J
a. Disconnect the ground cable from the transmission.
b. Remove the alternator.
❖•❖•❖;
Jack up the front end of the car and place blocks
W••••
under the body.
~.•N
!.'NN
Remove the screw for the gear selector wire at the
1
transmission. Move the gear selector lever to position "1" and pull out the sheath from the transmission. Fit tool 8790388 on the wire, turn the
tool a little and pull out the wire.
Detach the speedometer cable from the transmission.
Undo the engine brackets.
Undo the larger clips round the rubber bellows on
the inner universal joints.
Fit the lifting yoke 8392177 to the two engine
lifting lugs.
Undo the lower end piece from the control arm on
the right-hand side and turn the steering wheel to
the left and withdraw the universal joint, Lift the
power plant a little and withdraw the left universal
joint.
··•r
~N,
,W
Lift the power plant to a convenient height for access to the cable connections on the starter. Disconnect the cables.
Hoist out the power plant. Fit protective caps over
the inner drivers and rubber bellows.
442-1
Page 484
INSTALLING
The front of the car should be supported on blocks dur•
ing installation of the power plant.
1. a. Check that the inner universal joints are packed
with grease.
b. Check the front engine cushion. Make sure that
the washer is properly tightened.
2. Raise the power plant with the lifting yoke and
position the power plant in the engine compartment.
3. Lower the power plant to a convenient height for
fitting the starter. Connect the cables.
4. Assemble the inner universal joints as follows:
Hang the clips on the inner drivers. Lower the power plant until it is about 2-2 1/2" (50-60 mm)
from the engine cushions. Assemble the right-hand
universal joint, then lower the power plant until it
is about 1" (20-30 mm) above the engine cushions
and push the power plant to the right. Lower the
power plant and position it over the engine cushions
while guiding the left-hand universal joint into place.
Connect the end piece to the lower control arm.
5. a. Align the engine bFackets.
Cars built to U.S. specifications and other cars with
servo-assisted steering are equipped with special rear
engine cushions. The cushions are designed to prevent the power plant from hitting the steering gear
and damaging it in the event of a collision. A wire
runs between the rear edge of the upper retaining
plate and the front edge of the lower retaining plate
in the cushions. The position of the cushions is determined by guides in the engine bracket and the
cushion.
b. Bolt the power plant to the engine cushions.
Remove the lifting yoke.
a. Push the rubber bellows over the inner universal
joint drivers and fit the clamps.
b. Wipe any surplus grease off the rubber bellows
and check that the bellows are not deformed.
8. Connect the gear selector wire to the transmission.
9. Connect the speedometer cable to the transmission.
10. Bolt the exhaust pipe to the exhaust manifold.
11. Lower the front end of the car.
12. a. Connect the ground cable.
b. Fit the alternator.
13. Mount the front sheet complete with radiator and
. connect the hood lock operating cable to the attachment at the dash panel.
14. Fit the grille.
15. Reconnect the cables to the radiator fan, thermostat contact, headlights, headlight wiper motor and
clip the bundle of wiring to the front sheet.
16. Connect the coolant hoses to the radiator, thermostat housing, water pump, inlet manifold and heater.
6.
7.
442-2
17.
18.
19.
19.
20.
21.
22.
23.
24.
Connect the vacuum hose and fuel hose and connect cables to the temperature transmitter, ignition coil and oil pressure transmitter.
a. Connect the throttle control wire to driver and
bracket.
b. Carbureted engine:
Connect the choke control wire to the carbu•
retor.
Carbureted engine:
a. Mount the air cleaner and preheater complete
with hoses.
b. Connect the ventilation hose.
c. Connect the cables between the distributor and
ignition coil.
d. Connect the fuel pipe.
Injection engine:
a. Mount the air cleaner and mixture control unit
and connect the rubber bellows to the throttle
valve housing and the air flow sensor.
b. Fit the fuel lines.
c. Fit the cables to the warm-up regulator, auxiliary air valve, cold start valve, thermo-time switch
and air flow sensor.
Install the battery and connect the cables.
Close the radiator and engine block drain cocks,
fill with coolant and oil.
Start the engine, checking oil pressure and coolant
temperature. Check the operation of the transmission. Check the operation of the radiator fan by
grounding the thermostat contact cable to the radiator.
a. Mount the hood and connect the windshield
washer hose.
b. Check the fit of the hood. Close the hood, open
the doors, and check that the door jambs clear
the rear edge of the hood.
c. Check the headlight alignment.
Take the car out for a test run. Check the coolant
level after driving.
Page 485
SEPARATING ENGINE FROM AUTOMATIC TRANSMISSION
1. Clean the outside of the power plant.
2. Drain the engine oil.
3. Remove the cover over the flywheel ring gear.
4. Remove the starter.
5. Disconnect the throttle wire from the throttle valve
housing (carburetor).
6. Model 1975: Remove the tlTee screws in the release
bearing guide sleeve.
As from model 1976: Remove the three slave cylinder
retaining screws.
7. Model 1975: Remove the adjusting screw and the
clutch lever.
8. Remove all bolts in the mating flanges of the engine
and the transmission.
9. Lift the engine carefully off the transmission and remove the release bearing guide sleeve at the same time.
CAUTION
If the engine and transmission fail to separate, never
attempt to force them apart without first checking
that all bolts have been removed.
Reassemble in the reverse order.
When fitting together the engine and transmission:
Ensure that the mating flanges between the engine
and transmission are absolutely clean.
Check that the two dowels are fitted in the transmission casing.
Fit a new gasket on the transmission housing. Apply
sealing compound to both sides of the gasket as shown
in the illustration above.
Apply thread locking compound to the six bolts in
the holes as indicated in the lower illustration.
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442-3
Page 486
TRANSMISSION CONTROL
1. Remove the gear selector lever cover.
2. Slack off the gear selector lever housing nuts with tool
8391237.
3. Lift the gear selector lever housing and turn it so that
the adjustment nuts of the wire will be accessible.
4. Adjust by screwing the nuts on the outer cover so
that this will be displaced inwards or outwards.
5. After adjusting, the gear selector lever housing will be
reassembled, and the clearance in N and D will be
checked once again.
Automatictransmission
GEAR SELECTOR CABLE
Checking, types 393 and 399
1. Move the selector lever to N. Check the clearance
against the segment.
2. Move the selector lever to D. Check the clearance
against the segment. The clearance in N and the
clearance in D should be the same. See illustration.
3. Check that P, R, 2 and 1 are in correct position.
ADJUSTING THE GEAR SELECTOR LEVER CABLE
S 3199
In the connect between the gear selector lever cable
and the automatic transmission case a fine setting can be
done. Fine setting of the gear selector lever cable is possible in the connection between the cable and the automatic transmission case. Undo the set screw and turn the adjusting nut.
ADJUSTING THE GEAR SELECTOR LEVER HOUSING
1. The clearance in N and in Dare the same.
Adjusting, types 393 and 399
SECTION THROUGH GEAR SELECTOR LEVER HOUSING
P = Park
R
Reverse
N
Neutral
D
Drive 1, 2, 3rd
Drive 1, 2nd
2
Drive 1st
FINE SETTING OF THE GEAR SELECTOR LEVER CABLE
1. Adjusting the wire with nut
444-1
SA-.S
.L
Page 487
TRANSMISSION CONTROL
Automatic transmission
GEAR SELECTOR CABLE
Change type 487
1. Move the selector lever to N. Press the pawl button
and move the lever slightly back and forth until you
hear a click and feel that the selector valve has locked
in position N.
2. Release the pawl button: the lever should now be
exactly in position N.
If the lever needs to be moved to engage postion N,
adjustment is necessary.
An additional
notch has been incorporated
in the le-
ver segment for position N and is readily detechable
when the pawl button is released. This is to enable
adjustment of the lever position.
S.MI
L
444-2
Page 488
\
Gear selector cable, adjustment, type 487
1. Move the selector lever to N. Press the pawl button
and move the lever slightly back and forth until you
hear a click and feel that the selector valve has locked
in position N.
2. Hold the lever completely still in this position, with
the pawl button depressed.
3. Undo the cable attachment
bit adaptor 87 90 883.
at the lever using hexagon
4. Release the pawl button and move the lever to position N.
An additional notch, indicating the exact position
of N, has been incorporated in the lever segment
to facilitate adjustment of the gear selector cable.
5. Tighten the set screw for the gear selector cable using
a torque wrench and hexagon bit adaptor 87 90 883.
Tightening torque
444-3
2.5 Nm (1.8 ft.lb.,
0.25 kpm)
------~
SAAB
Page 489
GEAR SELECTOR CABLE
6. Connect the wire to the gear selector rod and the housing.
Then adjust the cable to roughly the correct position
with P engaged in the transmission.
7. Screw on the selector lever housing and check the
selector lever in the various positions, readjusting if
necessary (see directions for adjusting the gear selector
cable).
Change, types 393 and 399
1. Remove the gear selector housing so that the cotter
pin securing the wire to the gear selector rod can be
driven out. Then disconnect the cable from the housing by undoing the two screws holding the wire clamp.
2. Disconnect the cable from the transmission casing using
the special tool 8790388.
GEAR SELECTOR CABLE
Change, type 487
1. At the transmission casing:
a. Remove the cable attachment bolt at the transmis·
sion casing.
b. Pull the wire and the selector cable to the outer position (position P).
c. Slide back the spring-loaded sleeve on the gear shift
rod and unhook the cable end piece.
REMOVING THE GEAR SELECTOR LEVER CABLE
Tool 8790388
3. Take off the heater duct and remove the old cable.
4. Fit a new cable, being sure to obtain a perfect seal
where it passes through the toeplate, and replace the
heater duct.
2. At the gear selector housing:
a. Remove the gear selector housing using special
sleeve 87 90 370.
b. Remove the circlip from the end of the cable on
the underside of the lever housing.
S 3202
GEAR SELECTOR LEVER CABLE WITH CLIPS
5. Connect the cable to the transmission and then pull
out the wire to engage position Pin the transmission.
""'
c. Remove the locking screw where the cable is attached
to the selector lever.
SAAB
444-4
Page 490
d. Loosen the cable sheath nuts and release the cable.
3. Remove the carpet, heater duct and the old cable and
fit a new one. Make sure there is a good seal at the
point where the cable passes through the bodywork.
4. At the transmission casing:
a. Slide back the spring-loaded sleeve on the gear shift
rod, hook together the Iinks and release the sleeve.
REMOVING THE THROTTLE CABLE FROM VALVE HOUSING
4. Connect a new cable to the transmission casing and
hook it to its cam on the control valve, making sure
that the wire is properly positioned on the guide pulley.
b. Insert the cable sheath and fit the retaining bolt.
5. At the selector lever housing:
a. Insert the end of the cable in the attachment hole
in the gear selector rod and fit the circlip.
b. Secure the cable sheath to the housing.
6. Adjust the cable as follows:
a. Withdraw the gear selector cable as far as possible
(position P).
b. Move the cable two notches (position N ).
c. Move the gear selector lever to N and tighten the
bolt to the specified torque. The selector lever
housing should be in an upright position.
Tightening torque
2.5 Nm (1.8 ft.lb.,
0.25 kpm)
7. Refit the selector lever housing.
REMOVING THE THROTTLE CABLE FROM TRANSMISSION
CASE
5. Keeping the cable straight, increase the tension in the
wires until the cam moves, using a pair of pliers,
clamp the stop clip to the threaded part of the cable.
THROTTLE CABLE
Change
1. Disconnect the wire from the throttle and from its
attachment to the retaining plate.
2. Drain oil from the automatic transmission and take
off the forward bottom cover.
3. Disconnect the throttle wire from its cam at the control valve on the valve housing and unscrew the cable
from the transmission casing.
444-5
CLAMPING THE STOP CLIP ONTO THE THROTTLE CABLE
SAAB