Page 491
4. Move the selector lever to D.
6. Connect the wire to the throttle damper at the intake
manifold and adjust the wire roughly by noting the
position of the cam relative to the position of the
throttle damper. When the accelerator pedal is fully
depressed, i.e. in the "kick-down" position, the
highest point of the cam should be in contact with
the "kick-down" valve (sell illustration).
7. Refit the bottom cover to the oil sump and fill the
transmission with oil. For adjustment of the throttle
wire, see the relevant directions.
THE CAM IN "KICK-DOWN"
5. Read off the pressure on the pressure gauge.
6. Rev up from idling by 500 rev/min.
7. Read off the pressure again. ft should be up by 10-20
psi (0.7-1.4 bar, kp/cm2). If the pressure rise is too
little, the control cable must be adjusted outward, if
the pressure rise is too high, the control cable must
be adjusted inward.
NOTE
The pressure should be 50-70 psi (3.5-4.9 bar,
kp/cm2) in idling with gear selector lever in D.
POSITION
ADJUSTING THE THROTTLE CABLE, INJECTION ENGINE
1. Throttle wire. 2. Cam. 3. Valve.
GEAR SELECTOR CABLE
Adjusting
1. Connect a revolution counter to the engine and a pressure gauge to the transmission.
2. Immobilize the wheels by applying the brakes.
3. Start the engine and check that the idling speed is
properly adjusted.
ADJUSTING THE THROTTLE CABLE, CARBURETED
ENGINE
CONNECTING THE PRESSURE GAUGE
-
SA1ttB
444-6
Page 492
Identification table
The table below of dimensions and identification numbers has been compiled to help you tell the cables apart.
An identification number is stamped into the hexagon
nut at the end of the cable which is connected to the
transmission.
A
B
Identification
No.
S4550
Lengths
Transmission type
Cable No.
ldentification
No.
mm
in.
mm
in.
A
B
393 (carburetor and injection
engine versions with effect
from chassis numbers 99752022710,
99756007809 and 99757003050 and
type 487
8709107
210
1242.3
48.94
1029.9
40.55
399 (injection engine version up to
and including chassis numbers
99752022709,99756007808and
99757003049
8709099
211
627.1
24.64
430.0
16.93
GEAR SELECTOR LEVER HOUSING
Assembling
Removing
1. Move the ignition switch to Drive.
2. Assemble the gear selector housing with the bottom
cover and connect the wire bracket.
3. Attach the house with one or two screws. Check and
if necessary adjust the gear positions. See "Adjusting
the gear selector cable". Assemble the house.
4. Assemble the ignition switch cable. Move the gear
selector to P and take off the key.
5. Assemble the ignition switch light in the gear cover
and attach the cover.
6. ,Assemble the lamp socket and the scale light reflector.
7. Assemble the cable in the scale cover and attach the
cover.
8. Assemble the gear selector lever buttons and heater
control.
9. Assemble the floalt mat and battery cable.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Disconnect the battery earth cable.
Move the selector lever to P and take off the ignition key.
Loosen the lock nut under the button of the gear
selector lever and unscrew the button and nut.
Remove the scale cover. Before the cover can be
removed, the switch cable connections must be
loosened.
Remove the scale light reflector and the lamp socket for the scale light.
Remove the heater control lever button. The right
one is accessible when the control lever is in its rear
position and the right seat is in its front position.
Fold up the floor mat.
Remove the three gear cover retaining screws. Raise
the cover and take off the ignition switch lamp. Remove the cover.
Remove the ignition switch cable and note its position.
Remove the retaining nuts for the gear selector lever with tool 8391237.
Raise the gear selector lever housing and twist it.
Loosen the two bottom cover screws and take off
the wire bracket tension pin.
GEAR SELECTOR LEVER
Removal and installation
1. Remove the gear selector lever housing. See this section.
2. Turn the ignition key to Drive.
3. Take off the tension pin from the ratch sector.
4. Remove the screws and take off the lever.
Reassemble in reverse order.
444-7
s,r.na
Page 493
REMOVAL AND INSTALLATION
4-speed gearbox
Disassembling and assembling of the gear box can be done
without separating tbe engine and the gear box. The engine flywheel must first be removed.
IMPORTANT
Before disassembling the transmission, always measure up the positions of the pinion gear and crown
wheel. This is to check whether there is any error in
their locations. If the pinion and crown wheel assembly is relatively new, i.e. if it has done less than 6,000
miles (10,000 km), it can be adjusted, but if the mileage is any greater the gears will have worn themselves
into a given position. In the latter case, they should
be reassembled in the same measured positions which
they occupied before disassembly.
,
REMOVING THE DIFFERENTIAL
4.
DISASSEMBLING
ASSEMBLY
Remove the locking plate that holds the intermediate and reverse gear shafts in place (see illustration). Use tool 8390049 to withdraw the intermediate gear shaft so that the intermediate gear
set drops down.
(Proceed in the following order as far as necessary in order to remove whichever component needs attention:)
1.
2.
Clean off the transmission case and drain the oil.
Remove the differential bearing seat retaining
screws and remove the seat and inner driver using
tool 8390270 and extractor 8790776.
REMOVING THE LOCKING PLATE
REMOVING THE DIFFERENTIAL
BEARING SEATS
Tool 8390270 and 8790776
3.
Save the spring and plunger at the shaft end of the
driver, and the shims, which will be replaced on
the condition that the differential gear backlash
has not been altered by the exchange of some components.
Remove the differential assembly. For dismantling
of the differential assembly see section 473.
REMOVING THE INTERMEDIATE
GEAR SHAFT
Tool8390049
5.
Separate the transmission at the joints between
the gearbox and primary gear housing and lift away
the primary gear housing (see illustration).
471-1A
Page 494
Turn the gear selector rod so that the driver is detached from the reverse gear shift and pull out the
shaft.
SEPARATING THE PRIMARY GEAR HOUSING FROM THE
GEARBOX
6.
Remove the intermediate gear set (see illustration).
REMOVING THE REVERSE GEAR SHIFT SHAFT
Remove the shift shaft for the 1st-2nd gear 3rdtop gear and shift forks and remove the shift fork
and sliding muff for 3rd-top gear.
NOTE
The reverse lever need not be undone from the gear
shift shaft when the shaft is removed.
REMOVING THE INTERMEDIATE
7.
8.
GEAR SET
Unscrew the transmission side cover, take out the
spring and ball catch for the gear selector rod, and
put them in a safe place.
Undo the reverse gear shift shaft retaining screw.
REMOVING THE SLIDING MUFF FOR 3RD-TOP
9.
REMOVING THE REVERSE GEAR SHIFT SHAFT RETAINING
SCREW
471-2A
10.
GEARS
Pull out the reverse gear shaft. Use tool 8390049
to lift out the reverse gear.
Remove the needle bearing from the pinion shaft
and install tool 8790503 as a lock for the reverse
gear (see illustration), and undo the pinion shaft
nut .
.....
'
)
Page 495
INSTALLING
TOOL 8790503
PRESSING OUT THE PINION SHAFT
Tool 8790511
11.
Remove tool 8790503 and remove the 3rd-top
gear synchronization hub and 3rd gear.
REMOVING 3RD GEAR
12.
Undo the four pinion shaft bearing housing screws.
Install tool 8790511 and press out the pinion
shaft. Put the gears, sleeves, washers and shims in
a safe place.
SA1'B
471-3A
Page 496
Differences in number of cogs and
outer diameter (measured on the
cogs) between transmissions up to
and incl. model 1972 and transmissions as from model 1973.
Transmission model 1972
Serial No. up to and incl. 437751
Primary gear
No. of teeth
Transmission as from model 1973
Serial No. as from 500.000
No. of teeth
Outer diam.
Outer diam.
Input gear
20
2.276"
(57.8 mm)
20
2.318"
(58.9 mm)
Intermediate gear
48
5.151"
(130.8 mm)
48
5.118"
(130.0 mm)
Output shaft
19
2.276"
(57.8 mm)
20
2.318"
(58.9 mm)
Intermediate gear (tooth
surface engaged in first
gear)
17
2.224"
(56.3 mm)
16
2.181"
(55.4 mm)
First gear
30
3.626"
(92.1 mm)
30
3.665"
(93.1 mm)
Sliding wheel, reverse
14
1.890"
(48.0 mm)
14
1.906"
(48.4 mm)
Reversegear
34
4.166"
(105.8 mm)
33
4.154"
(105.5 mm)
Pinion
9
2.077"
(52.75 mm)
9
2.205"
(56.0 mm)
Crown wheel
38
6.914"
(175.6 mm)
35
7.047"
(179.0 mm)
and sleeve 8390148. Then insert and tighten the
four bearing housing screws.
ASSEMBLING
Having removed the component that needs attention,
clean all fragments of old gaskets and all traces of old
NOTE
.O.ny mA:1~11rinC1or r1diustina of the oinion shaft must
Inspect the transmission case and all disassembled parts
and wash them in kerosene or similar. Then reassemble
the transmission, following the procedure described below:
be done before the screws are secured with Loctite.
See section 473.
1.
2.
3.
Adjust the differential bearings to the correct compression. See section 473.
Screw the two locating studs (tool 8790438) into
the transmission case. Then shim and locate the
pinion shaft assembly. Tap the assembly gently into position, using a plastic metallet, drift 8390114
MOUNTING THE PINION SHAFT
Locating studs 8790438, drift 8390114, sleeve 8390148
471-4A
a. Before mounting the reverse gear on the pinion
shaft, the distance between the connecting surface for the primary gear housing and the pinion
shaft nut must be checked. The distance must
be 7.677"-7.681" (195.0-195.1 mm). If it is
not this distance, shims must be placed between
the nut and the reverse gear. Shims are available
MEASURING THE POSITION OF THE PINION SHAFT IN
THE GEARBOX HOUSING WITH DEEP GAUGE
&AMI
Page 497
5.
in thicknesses of 0.0118" (0.30 mm), 0.0157"
(0.40 mm) and 0.0197" (0.50 mm). If the position of the pinion shaft is unchanged, the shims
used earlier can be replaced.
b. When using measuring tool 8790552, the procedure of shimming is the following:
Install the measuring tool in the gearbox housing according to fig. and measure the distance
between tool and nut with the aid of a feeler
gauge. Fit shims with a thickness equvivalent
to that of the used feeler gauge.
6.
7.
8.
MEASURING THE POSITION OF THE PINION SHAFT IN
THE GEARBOX HOUSING WITH THE AID OF TOOL 8790552
4.
INSTALLING
SLEEVE FOR THE THIRD GEAR
Sleeve 8390148
9.
Install the reverse gear using sleeve 8390148.
10.
INSTALLING
Fit the 1st gear on the bearihg sleeve of the reverse
gear.
Fit 1st-2nd synchronization hub. Fit 1st-2nd gear
shift fork into 1st-2nd coupling muff and mount
these on the synchronization hub. Fit 1st-2nd gear
shift fork into 1st-2nd coupling muff and mount
these on the synchronization hub.
Install the 2nd gear sleeve with tool 8390148 and
mount the 2nd gear on the sleeve.
Fit the spacer, mount the sleeve for 3rd gear with
tool 8390148 and mount the 3rd gear on this sleeve.
Fit 3rd-4th gear synchronization hub.(Fit the syn_:
chronization hub fitted with the three locking holes
against the pinion nut.) Fit 3rd-4th gear shift fork
into 3rd-4th gear coupling muff and mount these
on the synchronization hub.
Install tool 8790503 at a lock for the reverse gear
and tighten the pinion shaft nut to the prescribed
torque of 40-60 Nm (30-45 ft.lb., 4-6 kpm) and
secure the nut. Install the pinion shaft needle bearing and its locking ring. Remove tool 87 90 503.
THE REVERSE GEAR
Sleeve 8390148
SAAB
471-5A
Page 498
14.
Check that the thrust washer for the intermediate
gear set is in the right place on the primary gear
housing. The washer can be glued on to facilitate
the fitting of the intermediate gear set. Check that
the connecting tube is fitted in the output shaft of
the primary gear.
TIGHTENING THE PINION SHAFT NUT
11.
12.
Ease the coupling muffs on the pinion shaft in the
neutral position and fit the gear shift shaft for 1st2nd and 3rd-4th gear shift forks.
Turn the gear selector rod clockwise so that there
is room to mount the reverse gear shift shaft.
Mount the latter. Tighten the axle with the stop
screw.
15.
NOTE
The reverse lever can be fitted to the reverse gear
shaft before the shaft is mounted in the gearbox.
13.
FITTING THE CONNECTING TUBE IN THE OUTPUT GEAR
OF THE PRIMARY GEAR SET
Mount the needle bearings in the intermediate gear
set with the help of grease so that they are held in
place until the intermediate gear set is fitted. Place
the intermediate gear set in the bottom of the gearbox.
NOTE
Leave the screws slightly slack to avoid jamming the
loose intermediate gear ~et in the wrong position before the intermediate gear shaft is inserted.
16.
INSTALLING
THE INTERMEDIATE
Coat the mating flange of the primary gear housing
with sealant compound, e.g. Tikatiit No. 2, and
screw the primary gear housing to the transmission
case.
Ease the intermediate gear into its correct position
either by turning the transmission housing or by
lifting the intermediate gear. Fit the rear thrust
washer and push in the intermediate gear shaft,
using tool 8390049.
GEAR SET
INSERTING THE INTERMEDIATE
Tool8390049
471-6A
SAAB
GEAR SHAFT
Page 499
17.
18.
Tighten the primary gear housing screws.
Install the reverse gear and shaft, making sure that
the reverse lever is fitted into the groove on the
reverse gear. Fit the lock plate over the reverse gear
and intermediate gear shaft ends. Se
with Loctite.
PINION SHAFT, 4-SPEED GEARBOX
Disassembling
To disassemble the pinion shaft, follow the instructions
already given for disassembling the transmission up to
the point where the pinion shaft is unscrewed. Then continue as follows:
1. Fasten fixture 8790636 and holder ring 8790651 in a
vice. Put the pinion shaft in the tool and loosen the
nut with the aid of tool 8790453.
S 5899
INSTALLING
REMOVING THE PINION BEARING NUT
THE REVERSE GEAR
Fixture 8790636, holder ring 8790651 and key 8790453
Fixture 8790636, holder ring 8790651
19.
20.
21.
22.
23.
Insert the spring and ball catch for the gear selector
rod and fit the transmission housing cover together
with its gasket.
Install the differential assembly (see section 473).
Inspect the shaft seals in the differential bearing
seats and fit new ones if necessary. Adjust the
crown wheel backlash if necessary (see section 473).
Mount the two inner drive shafts complete with inner universal joints, taking care not to damage the
shaft seals.
Fit the cover complete with gasket on to the transmission case.
Fill the transmission case with oil (5 Imp. pints,
3 liters).
SA.Ml
2. Put the unit in a press and press off the front roller
bearing with the help of sleeve 8390098, see illustration.
471-7A
Page 500
TOOLS 8390106, 8390148 AND 8390098
PRESSING THE SHAFT OUT OF THE BEARING HOUSING
Sleeve 8390098
3. Pressoff the rear roller bearing with the aid of tools
8790636 and 8790651.
PINION SHAFT WITH BEARING, BEARING HOUSING AND
SPACER SLEEVE
Installing the pinion shaft
Having removed the part that needs attention, inspect all
disassembled parts and wash them in kerosene or similar.
Then reassemble and install, proceeding as follows:
NOTE
The bearings must be oiled before being assembled.
1.
PRESSING THE REAR BEARING OFF THE SHAFT
Fixture 8790636 and holder ring 8790651
4. Pressthe outer rings of the conical roller bearings out
of the bearing housing using tools 8390098, 8390106
and 8390148 (see illustration).
471-BA
Pressthe outer races of the tapered roller bearings
into the bearing housing, using tools 8390189 and
8790461.