Page 501
PRESSING IN THE FRONT ROLLER BEARING
Sleeve 8390148
INSTALLING
THE BEARING RACE IN BEARING HOUSING
Drift B390189, sleeve 8790461
6.
2.
Fit the spacer washe·r and press on the roller bearing
nearest the pinion gear until it butts against its stop,
using tool 8390148 (see illustration).
7.
Set up the shaft in a press (see illustration). Press
the bearing housing slowly on, using tool 8390148,
and twist it at the same time until resistance to
twisting is felt.
Smear Loctite "stud lock" on the threads and put
on the nut. Install fixture 8790636 with holder
ring 8790651 in a vice. Place the bearing housing
on the fixture. Pull the nut with key 8790453 until
the correct torque is obtained.
Measure the torque by pulling the bearing housing
with the aid of a dynamometer. See fig. The bearings should be lightly oiled and tightened as follows:
.
, ..,
CHECKING THE BEARING HOUSING TORQUE
PRESSING ON THE ROLLER BEARJt,IG NEAREST THE
PINION GEAR
Fixture 8790636,
holder ring 8790651 and dynamometer
Sleeve 8390148
3.
4.
5.
Fit the spacer on the shaft.
Fit the bearing housing.
Fit the front roller bearing.
SAAB
471-9A
Page 502
New bearings 47-71 N (10-15 lb., 4.7-7.0 kp) on
the dynamometer which corresponds to a torque
of 2.5 ± 0.5 Nm (2 ± 0.5 ft.lb., 25 ± 5 kpcm). Old
bearings that have done more than 1,200 miles
(2,000 km) 19-43 N (4.2-9.2 lb., 1.9-4.3 kp)
dynamometer reading which corresponds to a torque of 1.3 ± 0.5 Nm ( 1 ± 0.5 ft.lb., 13 ± 5 kpcm).
When the correct value is obtained, upset the flange
of the nut with a drift.
PRIMARY GEAR CASE, 4-SPEED GEARBOX
Removal
To remove the primary gear case, follow the instructions
for dismantling of the gearbox. Accordingly, the differential assembly and the intermediate shaft assembly
must be removed before the primary gear case can be
dismantled.
Dismantling of primary gear - gear train {up to and incl.
gearbox No. 817000).
1.
Separate the bearing housing from the primary gear
case (see illustration).
LOCKING THE PINION BEARING NUT
-::~_._. ~
8.
~·
Fit two locating pins, tool 8790438, in the gearbox
housing. Then fit on the shims and mount the pinion shaft with. bearing housing. Knock the bearing
housing carefully into place using a plastic mallet
or hammer together with drift 8390114 and sleeve
8390148. Then tighten the four screws.
OPENING THE PRIMARY GEAR HOUSING
NOTE
Any measuring or adjusting of the pinion shaft must
be done before the screws are secured with Loctite.
See section 473.
NOTE
Remember to undo the clutch adjustment nut.
PRIMARY GEAR TRAIN
1. Input gear
2. Center wheel
3. Output gear
471-10A
...
Page 503
2.
3.
Remove the center wheel shaft from the bearing
housing and back off the center shaft nut so that
the center wheel can be taken off.
Pressthe outer races of the tapered roller bearings
out of the center wheel with drift 8390189 and
sleeve 8790478, using tool 8390098 as a support.
5.
Pressthe input gear complete with ball bearing out
of the bearing housing, using drift 8390122, sleeve
8390148 and support 8390098 (see illustration).
S 2452
PRESSING OUT THE INPUT GEAR
PRESSING OUT THE GEAR
Drift 8390122, sleeve 8390148, support 8390098
Drift 8390189, support 8390098
4.
Remove the cap from the bearing housing, free the
lock ring from the shaft and press the output gear
out of the bearing, using tool 8390098 as a suppott and pressing with drift 8390189 (see illustration). Then press the bearing out of the bearing
housing.
6.
Undo the lock ring from the input gear and press
the ball bearing off the gear, using supports
8390098 and 8390247 and drift 8390189 (see illustration).
Use tools 8390189 and 8790460 (see illustration).
PRESSING THE BEARING OFF THE INPUT GEAR
Drift 8390189, supports 8390098 and 8390247
PRESSING OUT THE BEARING FROM THE BEARING
HOUSING
Drift 8390189, sleeve 8790460
&AMI
471-11A
Page 504
7.
8.
Remove the bearing support that retains the gearbox input gear (4th) with bearing.
Press the gearbox input gear (4th) out of the primary gear housing, using ring 8390213 and drift
8390189. Release the lock ring and press the bear•
ing off the shaft, using ring 8390213 and drift
8390189.
REMOVING THE ROLLER BEARING
Drift 8390320, support 8390098
Assembly of primary gear - gear train (up to and incl.
gearbox No. 817000).
Having removed whichever part needs attention, clean
the mating flange surfaces of the cover to remove gasket
fragments and traces of sealant compound. Inspect all
disassembled parts and wash them in kerosene or similar.
Then reassemble as follows:
1. Fit the needle bearing with tool 8790479 and
drift 8390189, and the oil collector into the
primary gear housing if they have been removed.
REMOVING THE BEARING FROM THE INPUT GEAR
Drift 8390189, ring 8390213
1.
9.
If necessary, remove the oil collector and needle
bearing from the primary gear housing.
The needle bearing has been discontinued with effect from 1976 model cars.
NOTE
The needle bearing in the primary gear housina has
been discontinued in cars as from model 1976.
It is no longer necessary to install the bearing in ,conjunction with the overhaul of transmissions of earlier
design.
When the gears in the primary gear assembly in transmissions of earlier design are to be replaced, the
needle bearing must be removed, since the bearing
surface on the shaft has not been machined.
2.
REMOVING THE NEEDLE BEARING
10.
Press out the input gear roller bearing from the primary gear housing, using tool 8390320 and support 8390098 (see illustration).
471-12A
Fit the oil collector into the primary gear housing
if removed.
SYS
Press the ball bearing on to the input gear of the
gearbox (4th). using sleeve 8790487. Fit the bear-
Page 505
S3810
MOUNTING THE BEARING ON THE INPUT GEAR
Sleeve 8790487
PRESSING ON THE BALL BEARING
Sleeve 8390148
ing lock ring and press the gearbox input gear {4th)
complete with bearing into the primary gear housing, using tool 8390122.
5.
Pressthe primary input gear complete with ball
bearing into the bearing housing, using sleeve
8390098 and ring 8390247 and a suitable support
between the sleeve and the press head. The bearing must be pressed in until it lies flush with the
mating surface of the bearing housing.
S3386
MOUNTING THE INPUT GEAR AND ITS BEARING INTO
THE PRIMARY GEAR HOUSING
Sleeve 8390122
3.
4.
Mount the bearing support for the ball bearing of
the gearbox input gear to the primary gear housing.
Apply sealing compound to the screws.
Pressthe ball bearing on to the input gear of the
primary gear unit, using sleeve 8390148, see illustration. Fit the lock ring.
PRESSING IN THE GEAR AND BALL BEARING IN THE
BEARING HOUSING
Sleeve 8390098 and ring 8390247
&AMI
6.
Pressthe output gear ball bearing into the bearing
housing, using tools 8J90148 and 8390114. Then
press the output gear into the ball bearing, using
sleeve 8790487 as support {see illustration). Then
fit the washer and lock ring.
471-13A
Page 506
MEASURING
THE TORQUE OF THE CENTER WHEEL
Dynamometer 8390130
S3896
Tighten and secure the nut with Loctite and upset
the flange of the nut with a drift when the dynamometer reading is 6-8 N ( 1.3-1.8 lb., 0.6-0.8 kp)
which corresponds to a torque of 0.4-0.5 Nm (34 in.lb., 4-5 kpm).
FITTING THE OUTPUT GEAR INTO THE BEARING
HOUSING
Support, sleeve 8790487
7.
Fit the outer roller bearing race in the center wheel,
using tool 8390320.
10.
11.
12.
13.
,....
FITTING THE BEARING RACE IN THE CENTER WHEEL
Drift 8390320
8.
9.
Fit the front roller bearing on to the center wheel
shaft. Then fit the center wheel and the outer roller
bearing.
Set up the center wheel complete with shaft and
bearing in a vice. Wind the cord round the cogwheel and pull the wheel round with a dynamometer (see illustration).
471-14A
SA.Ml
Fit the center wheel into the bearing housing and
tighten the screw and secure it with Loctite.
Press in the primary input gear roller bearing into
the primary gear housing if it has been removed,
using tool 8390320.
Coat the flange of the bearing housing with a sealing
compound, for example Tikatiit No. 2, and fit the
bearing housing into the primary gear housing.
Tighten the bearing housing cover.
Mount the primary gear housing on to the gearbox
and follow the instructions for assembly of the
gearbox.
Page 507
Dismantlingof primary gear - chain-drive(asfrom gearbox Nos. 900001 and S 00001 ).
1.
Undo the retaining bolts and remove the primary
gear housing cover.
REMOVING THE LOWER CIRCLIP
REMOVING THE COVER
2.
Remove the chain tensilmer.
REMOVING THE UPPER CIRCLIP
4.
Remove the 2 sprockets and the chains simultaneously. It may be necessary to use tapping-out
hammer 83 90 270 and tool 87 90 834 to remove
the sprocket
REMOVING THE CHAIN TENSIONER
3.
Remove the circlip from the lower sprocket wheel
and remove the circlip on the upper sprocket gear
through the opening in the sprocket.
REMOVING THE SPROCKET WHEEL
Tool 83 90 270 and 87 90 834
SftAB
471-15A
Page 508
REMOVING SPROCKETS AND CHAINS
THE BEARING IS PRESSED OUT OF THE PRIMARY GEAR
HOUSING
Tool 87 90 842
5.
Remove the bearing circlip on the upper primary
gear.
7.
Remove the 4 socket screws and remove the bearing
retainer at the input gear to the gearbox.
REMOVING THE CIRCLIP FROM THE UPPER PRIMARY
GEAR
REMOVING THE BEARING RETAINER AT THE INPUT GEAR
6.
8.
Press the bearing out of the upper primary gear
using sleeve 87 90 842.
471-16A
SAAB
Press the input shaft to the gearbox out of the primary gear case.
--
Page 509
10.
Remove the needle bearing circlip and use a drift to
knock the needle bearing out of the primary gear
case.
THE INPUT SHAFT IS PRESSED OUT OF THE PRIMARY
GEAR CASE
9.
Remove the circlip and press the ball bearing off
the input shaft.
THE NEEDLE BEARING LOCK RING IS REMOVED
11.
Remove the clutch shaft seal by means of a screwdriver.
THE CIRCLIP IS REMOVED
THE CLUTCH SHAFT SEAL IS REMOVED
THE BALL BEARING IS PRESSED OFF THE INPUT SHAFT
SUB
471-17A
Page 510
Assembly of primary gear - chain-drive (as from gearbox
Nos. 900001 and S 00001)
4. Press the input shaft with bearing into the primary
gear case.
1. Install a new clutch shaft seal using drift 83 91 997.
THE INPUT SHAFT IS PRESSED INTO THE PRIMARY GEAR
HOUSING
5. Fit the bearing retainer to the primary gear case.
Apply sealing compound to the screws.
INSTALLATION
OF CLUTCH SHAFT SEAL
Tool 83 91 997
2. Using drift 83 91 997, install the needle bearing with
circlip in the primary gear case, with the mark on the
needle bearing facing outwards.
3. Press the ball bearing onto the input shaft to the gearbox and fit the circl ip. Use sleeve 83 90 148 and ring
87 90 867
THE BEARING RETAINER IS MOUNTED TO THE GEAR
CASE
s 6820
THE BALL BEARING IS PRESSED ONTO THE INPUT SHAFT
Tools 83 90 148 and 87 90 867
471-18A
WB·