Page 531
PINION SHAFT
3. Press off the rear roller bearing with the aid of tools
8790636 and 8790651.
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.
PRESSING THE REAR BEARING OFF THE SHAFT
Fixture 8790636 and h0lder ring 8790651
4. Pressthe outer rings of the conical roller bearings out
of the bearing housing using tools 8390098, 8390106
and 8390148 (see illustration).
REMOVING THE PINION BEARING NUT
Fixture 8790636, holder ring 8790651 and key 8790453
2. Put the unit in a press and fixture 8790636 and press
off the shaft from the bearing housing.
TOOLS 8390106, 8390148 AND 8390098
PRESSING THE SHAFT OUT OF THE BEARING HOUSING
SAAB
471-98
Page 532
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.
6.
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.
7.
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:
New bearings 47-71 N (10-15 lb., 4.7-7.0 kp) on
the dynamometer which corresponds to a torque
PINION SHAFT WITH BEARING, BEARING HOUSING AND
SPACER SLEEVE
1. Press the outer races of the tapered roller bearings
into the bearing housing, using tools 8390189 and
8790461.
PRESSING ON THE ROLLER BEARING NEAREST THE
PINION GEAR
Sleeve 8390148
2.
3.
4.
5.
Press the ball bearing nearest the pin.ion gear to
stop. Use fixture 8790636 and holder ring 8790925.
Fit the spacer on the shaft.
Fit the bearing housing.
Fit the front roller bearing.
471-10B
SAAB
Page 533
PRIMARY GEAR CASE
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).
5-speed transmission
The primary gear housing should be removed when dismantling the gearbox. Remove the primary gear housing
complete with the following components from the gearbox:
A. Ball bearing
8. Needle bearing
C. Clutch shaft seal
D. Level control ball valve
These parts are to be removed as follows:
Dismantling
1. Remove the four countersunk Allen screws and remove the ball bearing retainer.
When the correct value is obtained, upset the flange
of the nut with a drift.
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.
S 7418
2. Drift out the ball bearing. Use drift 8390106 and sleeve 8390148.
SA.1'B
471-11B
Page 534
Installation
1. Fit the ball bearing with the bearing retainer. Seal the
two retaining bolts with thread sealant. Gradually pull
down the bolts alternately until the bearing is in position.
3. Remove the needle bearing sleeve in the primary gear
case by means of drift 8391997 and 8390577.
Do not remove the level control ball valve. Just check
that the ball can be removed and that sits securely on
its seat.
The ball valve acts at low speeds downhill to prevent
the oil from running out of the gearbox and into the
primary gear housing, so ensuring proper lubrication
of the differential and final drive units.
4. Remove the clutch shaft seal by means of a screwdriver.
471-12B
SAAB
2. Fit the needle bearing race with the numbered end
pointing out towards the primary gear housing.
Use drift 8391997 and sleeve 7841067.
Page 535
3. Install a new clutch shaft seal. Installation tool 8399997
Grease the lips of the-seal after the installation. See
Lubricant Specification.
3. Use hollow drift 8790891 to press out the bearingfrom
the primary gear wheel.
Assembly
1. Fit the circlip to the upper primary gear wheel and
press the bearing into the wheel, see illustration.
Tool, hollow drift 8790859. Fit the circlip for the
bearing's outer race with the bevel facing outwards.
PRIMARY GEAR - CHAIN DRIVE
Dismantling
1. To dismantle the primary gear separately. Remove
the front cover from the primary gear housing and
the gearbox cover. Otherwise follow the instructions
under "Dismantling the gearbox".
2. Remove the circlip from the upper primary gear wheel.
2. Fit the chains, wheels and chain tensioner as described
under "Gearbox assembly".
3. Top up with oil.
srw
.i
471-138
Page 536
I
INPUT SHAFT BEARING HOUSING
2. Press the rear bearing off the input shaft. Use support
8790636 and ring 8790933.
Removing
1. Remove the oil catcher from the bearing housing and
press the input shaft out of the bearing housing. Retain the front bearing, the distance piece and the
shims. Use the ringshaped support 8390098. Take
care that the connection pipes are not damaged when
pressing out the shaft.
3. Remove the bearing races from the housing with a
drift. Rest the housing on the ring-shaped support.
471-148
SAAB
Page 537
2. Press the bearing races into the bearing housing. Use
tool 8390312, 8390189 and the ring-shaped support.
5
2
0
3
o,
6
7
8
PRIMARY CH.AIN DRIVE
1. Connecting pipe, lubrication
2. Input shaft
3. Ball bearing
4. Race
5. Bearing housing
6. Shims
7. Distance piece
8. Ball bearing
9. Race
1O: Chainwheel
11. Nut
12. Rear oil catcher
13. Front oil catcher
14. Bolts
Assembly
1. Press the rear bearing onto the shaft. Use drift 7841075
and the ring-shaped support.
UNI
3. Fit the input shaft, shims, distance piece and bearing
in the bearing housing. Select shims and distance piece of known size so deliberately giving axial play.
Place the shims between the rear bearing and the distance piece.
471-158
Page 538
I
4. Lubricate the bearings and press them together until
they meet the distance stop with 3 tons pressure applied.
While the bearings are being pressed together rotate
the bearing housing, against both the upper and lower
bearings, 40 times in both directions so that the balls
become properly positioned. Use drift 7841075 and
the ring-shaped support to avoid damaging the connecting pipes. Maintain the 3 tons pressure.
6. Press the front bearing off the input shaft and fit the
number of shims estimated. Place the shims between
the rear bearing and the distance piece. Refit the front
bearing on the input shaft in the bearing housing and
press together with 3 tons pressure. Rotate the bearing as described in point 4. Ensure that there is no resistance to movement or play in the bearing.
7. Fit the oil catcher in the bearing housing.
5. Install the gauge in the bearing housing bolt hole.
First put the bearing housing under load on the upper
bearing and then on the lower bearing while reading
off the axial play.
GEAR SELECTOR MECHANISM
The gear selector mechanism consists of a system of selector shafts, selectors, selector forks with plungers, selector balls, ball springs and taper setscrews.
3
~
6
10
7
8
5
a,,
!,2 ll13
1. Selector fork 1st and 2nd speeds
2. Selector fork 3rd and 4th speeds
3. Selector fork 5th gear
4. Actuator, reverse gear
5. Actuator, 5th gear
6. Shaft, 1st and 2nd, 3rd and 4th
speed selector forks
7. Shaft, reverse actuator and 5th
speed selector
471-168
...
9\1'11
U,4
8. Selector shaft
9. Reverse operating lever
10. Taper setscrew, shaft item 7
11. Ball, selector
12. Spring, ball
13. Plunger
14. Locking stud
Page 539
SELECTOR SHAFTS
Gear selector forks 1st, 2nd, 3rd, 4th and shaft
Dismantling
Se removal, installation
Knock out the dowel with a 4 mm drift. Remove the
spring, double lockout and selector.
GEAR SELECTOR FORKS 5TH GEAR
Reverse gear lever, ratchet ball, retaining spring and
guide lug.
1. Shaft
2. Tooth
3. Double lockout
Dismantling (can be performed with the gearbox in situ
or removed from the car)
1. Run off the oil.
2. Remove the gearbox side cover.
3. Remove the double lock out and the ball bearing. Remove the ball using a magnetized rod.
4. Remove the reverse operating lever pivot bolt and remove the lever from the actuator.
5. Push the reverse actuator rearwards on its shaft and
let it hang downwards.
6. Remove the primary gear housing side cover.
7. Remove the taper setscrew from the selector fork.
8. Rotate the 5th speed selector so that it points outwards and then push it rearwards until it stops. The
fork can now be released from the shaft and removed.
4. Spring
5. Actuator
Assembly
Installation
Assembly is in the reverse order. For positioning of parts
see illustration. Fit new dowels.
Assembly is in the reverse order. Lock the reverse operating lever pivot bolt with locking fluid.
Reverse actuator and 5th speed selector
Remove the 5th speed selector. The reverse actuator is
removed complete with selector shaft.
The countershaft gears and shaft plus the reverse wheel
and spindle must also be removed in order to refit the
reverse actuator and 5th speed selector.
REPLACING THE SEAL AND PLASTIC BEARING ON
THE GEAR SELECTOR ROD
(Can be done in car or on a removed gearbox)
Removal
Remove the axial play by inserting shims. These are
available in thicknesses 0.10, 0.15, 0.25 and 0.50 mm.
With the correct shims the bearing should not have the
slightest resistance to rolling or play. If the axial play
cannot be removed by inserting shims, the distance
piece is to be replaced. The distance piece is available
in the following lengths: 8.08, 8.09, 8.10, 8.11 mm.
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 .
...
471-178
Page 540
/
Disassembling
.al
2
3
1. Plastic bushing
2. Sealing ring
The synchronizing ring is removed by undoing the lock
ring which attaches the synchronizing ring to the gear.
The 5th speed synchro cup is dismantled by removing
the circlip in front of the guide ring. The circlip retaining the synchro cup should not be removed.
4
3. Removing tool
4. Installing tool
3. Put the removing tool 8790677 over the collar on the
sealing ring and screw in the screw of the tool against
the shaft.
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.
5. The plastic bearing is now accessible for dismantling.
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.
Fitting
1. Fit the plastic bearing.
2. Fit the new sealing ring with the aid of installing tool
8790685 and a suitable hammer.
3. Fit the differential housing cover.
4. Put together the gear shift rod joint and the gear selector rod ancf fit the taper pin.
5. Fill up the transmission with oil.
NOTE
Before refitting remove any burrs or marks on the
gear selector rod.
SYNCHRONIZATION
Synchronizing rings
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.
The 5th speed synchro cup can be replaced once the input shaft has been removed. It is consequently not necessary to remove the primary gear housing.
471-188
SUB
S3404
POSITIONING OF A SPRING END IN THE SPACE BETWEEN
THE TEETH OF THE RING