Page 511
6. Install the circlip in the upper sprocket and press in
the bearing (see illustrationi. Use sleeve 87 90 859.
Fit the circlip for the outer bearing ring in the sprocket, with the chamfer facing outwards.
MOUNTING THE CIRCLIPS
INSTALLING
THE CIRCLIP FOR THE BEARING OUTER RING
8. Install the chain tensioner. Install the chain tensioner
housing with the oil passage at the top and place the
backing plate so that its top edge is in line with the
top edge of the chain tensioner housing.
7. Mount the chains on the sprockets and mount the
latter onto the splines and stud, respectively, in the
primary gear case. Fit the two circlips.
CHAIN TENSIONER
Apply thread sealant to the chain tensioner bolts.
MOUNTING THE SPROCKETS AND CHAINS
471-19A
Page 512
9. Fit the gasket and the primary gear case cover.
NOTE
Before mounting the clutch slave cylinder, apply
thread sealant to the bolts.
REMOVAL OF PRIMARY GEAR WITH POWER PLANT
INSTALLED IN THE CAR
SEPARATING THE PRIMARY GEAR HOUSING IN CAR
Removal
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Remove the hood, battery and front sheet (see section 201 ).
Unbolt the exhaust pipe from the exhaust manifold
and disconnect the intake hose from the carburetor (rubber bellows from throttle housing, on cars
with injection engines).
Remove the alternator.
Undo the nuts on the engine mountings and engage
the lifting yoke in the engine lifting lugs. Balance
the yoke in such a way that the clutch end will be
lifted first and that the weight will be taken from
the rear end immediately, before the cylinder head
comes into contact with the bulkhead.
Remove the front engine mounting from the engine beam (and transmission for chain-drive).
Raise the power plant sufficiently to enable the
primary gear housing,the cover on chain transmission, to be withdrawn over the front engine beam.
Check that no parts become stretched or niooed.
Remove the lock ring (retaining clip) and clutch
shaft sealing cover. (O-ring) at the clutch shaft.
Unscrew the plastic propeller and remove the O-ring
at the clutch shaft end.
Withdraw the clutch shaft using tool 8390270 and
joint 8790529.
Remove the primary gear case retaining bolts and
bearing housing (cover) and separate the bearing
housing (cover) from the primary gear case.
471-20A
SAAB
Assembly
1. Check the mating surfaces of the primary gear housing/
cover and bearing housing for damage and ensure that
they are clean. Coat the sealing surfaces with a sealing
compound.
2. Mount and bolt the bearing housing cover to the primary gear housing.
3. Mount the front engine mounting to the transmission
(gear-train) and its rubber cushions to the engine
beam.
4. Lower the power plant and bolt it to the engine mountings.
5. Install the clutch shaft and plastic propeller.
6. Fit the cover, O-ring with lock ring, (lock clip) to the
clutch shaft.
7. Mount the alternator, exhaust pipe and intake hose
(rubber bellows on cars with injection engines).
8. Mount the front sheet, hood, and battery, and fill the
radiator with coolant.
Page 513
CHANGING THE CLUTCH SHAFT SEALING RING
Remove the clutch, clutch plate, release bearing and slave
cylinder (guide sleeve) as described on page 411-2.
Model 1975
Removal
Pry the sealing ring from the guide sleeve using a screwdriver, for example.
Installation
Press the sealing ring into the guide sleeve using tool
83 90 320.
REMOVING THE SEALING RING, MODEL 1976-1977
Instal lat ion
Press the sealing ring into the washer by means of tool
83 90 320. Use a piece of tubing which fits into the
groove for the primary gear case bearing as a support.
S 3211
INSTALLING
THE SEALING RING IN THE GUIDE SLEEVE
Model 1975, drift 83 90 320
Models 1976-1977
mary gear)
(and model 1978 with gear-train priINSTALLING
THE SEAL RING IN THE SEALING WASHER
Model 1976-1977,
Removal
Remove the washer and sealing ring from the primary
gear casing by means of polygrip pliers. Then separate
the sealing ring and O-ring from the washer.
drift 83 90 320
Fit the O-ring in the groove in the outside of the sealing
washer. Grease the lip of the sealing ring and fit the
sealing washer.
SAAB
471-21A
Page 514
As from model 1978 (transmission with chain drive primary
GEAR SHI FT MECHANISM
gear).
The gear shift mechanism consists of gear shift forks,
shafts and a selector rod with a spring-loaded ball catch.
Removal
Remove the clutch shaft seal by means of a screwdriver.
Disassembling
1. Clean off the transmission case and drain the oil.
2. Remove the differential bearing seat retaining screws
and remove the seat and inner driver using tool 8390270
and extractor 8790776. 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.
3. Remove the differential assembly. For dismantling of
the differential assembly see section 473.
THECLUTCHSHAFTSEALISREMOVED
Assembly
1. Install a new clutch shaft seal using drift 83 91 997.
DISASSEMBLING
THE DIF!=ERENTIAL
4. Remove the lock plate that holds the intermediate and
reverse gear shafts and pull out the intermediate gear
shaft, using tool 8390049, so that the intermediate
gear drops out.
INSTALLATION
OF CLUTCH SHAFT SEAL
Tool 83 91 997
All models
Refit the clutch, clutch disc, release bearing and guide
sleeve according to description on page 411-3.
REMOVING THE LOCK PLATE
471-22A
l-
SAAB
Page 515
7. Undo the reversegear shift shaft retaining screw. Turn
the gear selector rod to free the driver from the reverse gear shift and pull out the shaft.
REMOVING THE INTERMEDIATE
GEAR SHAFT
Tool 8390049
5. Separate the primary gear housing from the transmission case and lift it off. Remove the intermediate gear.
REMOVING THE REVERSE GEAR SHIFT SHAFT RETAINING
SCREW
'1'.'t'.'.'
111111
11111
jj
",",
,1..1,
SEPARATING.THE PRIMARY GEAR HOUSING FROM THE
TRANSMJSSION CASE
REMOVING THE REVERSE GEAR SHIFT SHAFT
6. Unscrew the transmission side cover, take out the
spring and ball catch for the gear selector rod, and
put them in a safe place.
Remove the shift shaft for the 1st-2nd gear and 3rdtop gear shift forks together with the shift fork for
3rd-top gear.
NOTE
The reverse lever need not be undone from the gear
shift shaft when the shaft is removed, but can be removed afterwards by undoing the screw which holds
the reverse lever to the shaft.
REMOVING THE GEAR SELECTOR ROD SPRING
SA.ft&
471-23A
Page 516
I
S3390
GEAR SHIFT MECHANISM FOR REVERSE GEAR
REVERSE-BRAKE DEVICE
8. Remove the locating stud for the pawl shaft and re•
move the latter by withdrawing it from the gear se•
lector rod. The gear selector rod can be removed from
the transmission case without the driver being taken
away. The cotter pin in the driver can then be re•
moved by using a drift or similar tool.
9. If the gear shift fork for 1st-2nd gear has to be re•
moved, the pinion shaft must be removed (see section
on disassembling the transmission).
Assembling
1.
REMOVING THE COTTER PIN FROM THE DRIVER
2.
As from gearbox No. 900001 (and S 00001) in model
1978 with chain-drive primary gear, the reverse-brake
spring is also fixed to the gear'selector rod.
471-24A
SAAB
Install the pinion shaft, shims and reverse gear, 1st
gear and synchronizing hub. Fit 1st-2nd gear-shift
fork into 1st-2nd gear coupling muff and mount
these on to the synchronizing hub. Install sleeve
and 2nd gear, spacer and sleeve and 3rd gear and
3rd-4th gear synchronizing hub. (As from gearbox
No. 500.001 the synchronization hub locking holes
are turned against the nut.) Put 3rd-top gear shift
fork into 3rd-top gear coupling muff and mount
these on to the synchronizing hub. Smear Loctite
on the threads and tighten the pinion shaft nut to
a torque of 40-60 Nm (30-45 lb., 4-6 kpm) and
secure it. Install the needle bearing and lock ring
on to the pinion shaft.
Fit the driver (pawl and reverse-brake spring) to the
gear selector rod.
Insert the gear selector rod in the gearbox and fit
the (pawl and) locating stud. Ensure that the lo·
eating stud is the right way up, since the gear selec·
tor rod will otherwise be jammed when the cover
is fitted.
Page 517
Fit the reverse gear shift to the shaft. Turn the selector rod clockwise so that there is room to mount
the reverse gear shift shaft. Mount the latter. Make
sure that the reverse lever engages the groove on the
reverse gear.
Tighten the shaft with the stop screw. Seal the
screw with Loctite.
FITTING THE LOCATING STUD
3.
4.
Slide the coupling muffs on the pinion shaft to
their neutral position and fit the gear shift shaft
for 1st-2nd gear and 3rd-top gear shift forks.
Fit the bearing sleeve and reverse lever to the reverse gear shift shaft and tighten the screw.
med lasvatska. Montera backens vaxelforare till
INSTALLING
5.
THE REVERS!'.: GEAR SHIFT SHAFT
Fit the needle bearing into the intermediate gear
with the help of grease so that it will be held in
place until the intermediate gear shaft is installed.
Then place the intermediate gear set in the bottom
of the transmission case.
S3390
GEAR SHIFT MECHANISM FOR REVERSE GEAR
INSTALLING
6.
SA.Ml
THE INTERMEDIATE
GEAR SET
Make sure that tile thrust washer tor the intermediate gear is in the correct place in the primary gear
housing. The washer can be glued in place to facilitate the installing of the intermediate gear. Check
also that the connecting tube is fitted into the output shaft of the primary gear.
471-25A
Page 518
8.
CAUTION
Intermediate shafts of later design (as from gearbox
No. 75818) are not provided with lubricating holes,
lubrication being effected by means of the washers.
When installing intermediate shafts not provided
with lubricating holes, always use thrust washers
with oil grooves.
9.
10.
11.
INSTALLING
7.
THE CONNECTING TUBE
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.
Fit the lock plate over the reverse gear and intermediate gear shaft ends. Secure the screw with
Tighten the primary gear housing screws.
Insert the spring and the bal I catch for the gear
selector rod and mount the transmission case side
cover together with its gasket.
Coat the flange of the primary gear housing with a
sealant compound, e.g. Tikatiit No. 2, and fit the
primary gear housing on to the transmission case.
FITTING THE SPRING FOR THE GEAR SELECTOR ROD
S 6190
12.
13.
NOTE
Leave the screws slightly slack to avoid jamming the
loose intermediate gear set in the wrong position before the intermediate shaft is inserted.
471-26A
SftAB
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.
Page 519
14.
15.
Fit the cover complete with gasket to the transmission case.
Fill the transmission case with oil (5 Imp. pints,
3 liters).
Installation
1. Fit the new sealing ring with the aid of installing tool
8790685 and a suitable hammer.
CHANGING THE SEALING RING, GEAR SHIFT ROD
(Can be done in car or on a removed gearbox)
Removal
1. Knock off the front taper pin from the gear shift joint
and separate the joint from the rod.
2. Pull off the rubber bellows from the collar on the sealing ring.
As from gearbox No. 780678 (with metal cover on
differential housing), the differential housing cover
must also be removed when the sealing ring is to be
changed.
3. Put the removing tool 8790677 over the collar on the
sealing ring and screw in the screw of the tool against
the shaft.
INSTALLING
TOOL 8790685
2. Fit the rubber bellows on the sealing ring.
3. Put together the gear shift rod joint and the gear shift
rod and fit the taper pin.
4. As from gearbox No. 780678, fit the differential
housing cover.
SYNCHRONIZATION
Synchronizing rings
REMOVING TOOL 87 90 677
N.B. As from gearbox.No. 780678, the differential housing
cover must also be removed.
4. Pry off the sealing ring with the aid of a screwdriver
held between the tool and one of the screw heads on
the rear cover.
When changing the synchronizing rings, follow the instructions for the dismantling of the gear box. The differential
unit must be removed and the intermediate gear disconnected so that the primary gear housing can be removed.
When changing the synchronizing ring for top gear, no
further dismantling is necessary.
When changing the synchronizing ring for 1st and 2nd
gear, the pinion shaft must be taken out of the transmission housing, so that the gears can be removed from the
shaft.
471-27A
Page 520
Disassembling
The synchronizing ring is removed by undoing the lock
ring which attaches the synchronizing ring to the gear.
S3404
POSITIONING OF A SPRING END IN THE SPACE BETWEEN
THE TEETH OF THE RING
REMOVING THE SYNCHRONIZING
RING FOR 3RD GEAR
Assembling
First fit the guide rings for the retaining springs, and the
lock rings for the guide rings on 3rd and 4th gear. First
and second gear have no lock rings for the guide rings.
The retaining spring is fitted with a long wire end nearest
the guide ring, and the spring is placed so that there are
eleven teeth between the ends of the spring. The zynshronizing ring is placed so that the ends of the retaining
spring fit into the spaces between the teeth, after which
the lock ring is fitted.
SYNCHRONIZATION,
CAUTION
The guide rings on the third and fourth gears are
assembled during production and are peened in position by a special tool after the lock ring has been
fitted. The guide rings supplied as spare parts should
not be peened.
471-28A
1ST AND 2ND GEARS
1. 2nd gear
2. Guide ring
3. Retaining spring, 2nd gear
4. Synchronizing ring
5. Lock ring
6. ?Ynchronizing hub
7. Coupling muff
8. Retaining spring, 1st gear
9. 1st gear
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