Page 541
CAUTION
The guide rings on th& 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.
2
Fit the 5th speed synchro ring. The retaining spring should
be positioned so that there are 5 teeth between the ends
of the spring. Then fit the guide ring and the circlip.
NOTE
The 2nd speed synchro cup has its synchronizing
surface covered with molybdenum and this, together with a difference in the machining, enables
it to be distinguished from the other synchro cups.
1. Operating sleeve
2. Circlip
3. Synchro cup
4. Synchro hub
3
4
5
6
7
5. Retaining spring
6. Guide ring
7. Circlip
VENTILATION
Ventilation of the transmission is by means of a hole
through the top cover in the primary gear. The hole
emerges·at the centre of a plastic propeller which is
bolted to the clutch shaft.
As the clutch shaft rotates, the oil is flung away from
the hole by the propeller.
When the shaft is stationary, the oil level in the primary
gear is considerably below the hole.
With effect from transmission numbers 649792 (cars
from the latter half of 1975 model), a washer has been
installed between the vent cover and the bearing. This is
to prevent leakage occurring as a result of the oil level
having been raised in the primary gear housing.
I S3406
SYNCHRONIZATION,
1ST AND 2ND GEARS
1. 2nd gear
2. Guide ring
3. Retaining spring, 2nd gear
4. Synchronizing ring
5. Lock ring
6. Synchronizing hub
7. Coupling muff
8. Retaining spring, 1st gear
9. 1st gear
4 5
6
S3400
SYNCHRONIZATION,
3RD GEAR
1. Lock ring
2. Synchronizing ring
3. Retaining spring, 3rd gear
4. Guide ring
5. Lock ring guide ring
6. 3rd gear
5"1111
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471-198
Page 543
DISASSEMBLY, ASSEMBLY,
5.
Remove the wheels.
ADJUSTMENT
Automatic transmission
Concerning removal and installation of power plant, see
section 442.
The following special operations are described at the end
of this section:
Dismantling and checking the governor (transmission
in car)
Dismantling and assembling the valve housing (transmission in car)
Dismantling and fitting the front band and rear clutch.
REMOVING THE PRIMARY GEAR
DISASSEMBLY
1.
2.
3.
4.
Drain oil.
Invert gearbox and remove front and rear bottom
covers.
Remove front cover.
Undo retaining screw and nut for sprocket wheels,
using tool 8790230 to lock.
NOTE
Gear unit axial clearance must be checked before
each disassembly.
6.
7.
UNDOING THE SCREW FOR PRIMARY GEAR
Remove cover on right-hand side.
Disconnect throttle valve control cable.
REMOVING THE THROTTLE CABLE FROM VALVE HOUSING
Support 8790230
8.
9.
51\AEI
Remove all oil pipes inside the front bottom cover.
The three pipes inside the rear bottom cover is to
be removed later.
Undo the three retaining screws from the valve housing, lift the housing straight up and remove the two
large oil pipes from the pump.
472-1
Page 544
I
LOCATION OF OIL PIPES
REMOVING THE RETAINING SCREWS OF THE VALVE HOUSING
472-2
UAB
Page 545
OIL PIPE BETWEEN VALVE HOUSING AND OIL PUMP
10.
11.
12.
Turn gearbox right way up, undo the three oil pump
retaining screws, and remove the pump. Lift the
torque converter at the same time to make the work
easier.
Lift out the torque converter.
If necessary, disconnect throttle cable.
REMOVING TORQUE CONVERTER HOUSING
15.
16.
17.
Remove gasket.
Undo automatic adjustment screw, see illustration.
Remove front band lever shaft.
REMOVING THROTTLE CABLE FROM TRANSMISSION
CASING
13.
14.
Remove retaining screws from torque converter
housing (five outside and five inside).
Before lifting out the housing, pull the gear selector
rod as far forward as possible. Remove the three
remaining oil pipes and at the same time remove
the converter housing.
REMOVING FRONT BAND LEVER SHAFT
472-3
Page 546
18.
Unhook rear band spring,
____
S2642
SCREW FOR CENTRE SUPPORT
21.
Remove the front clutch. Take care of the axial
washer (washers). There are two different designs,
the one washer of the later design is thicker and
supersedes the two washers on the earlier design
as spare part.
REMOVING THE SPRING
19.
Remove rear band lever shaft, removing the spring
at the same time.
REMOVING THE FRONT CLUTCH
22.
Remove the rear clutch with the shaft for the forward sun gear, holding the front band securely to
prevent it from falling over.
REMOVING REAR BAND LEVER SHAFT
20.
472-4
Undo the three screws securing the centre support.
Note that the screw in the engine oil sump is provided with a rubber gasket.
REMOVING THE REAR CLUTCH
s.,a
Page 547
23.
Remove front band.
25.
26.
27.
Remove the planet carrier, save the thrust washer
and bearing.
Remove rear band.
Remove the ring gear (valid only for earlier design).
On automatic transmissions of later design the ring
gear is removed together with the pinion bearing
housing.
REMOVING THE FRONT BAND
24.
REMOVING THE FRONT PISTON
Remove centre support, holding the planet carrier
in place by compressing the rear band.
28.
29.
Dismantle lock ring from front piston and remove
the piston with aid of compressed air.
Remove the rear piston with aid of compressed air.
REMOVING THE CENTRE SUPPORT
REMOVING THE REAR PISTON
SA-S
..L
472-5
Page 548
30.
If necessary dismantle the parking pawl shaft and
remove the parking pawl and·spri-ng.
31.
If necessary take off bearing houses and remove
differential and pinion shaft as stated below.
Remove the differential bearing seat retaining screws
and remove the seats and inner driver by means of
tool 8390270 and extractor 8790776. Save the
spring and plunger at the shaft ends of the drivers
together with the shims, which will be reused on
the condition that the differential gear backlash
has not been altered by the exchange of any components.
Remove the differential assembly. For dismantling
of the differential assembly, see section 473.
REMOVING THE PARKING PAWL SHAFT
REMOVING DIFFERENTIAL
BEARING SEATS
Puller 8790776, tapping-out hammer 8390270
PARKING PAWL
NOTE
If overheating or the like has occurred, the differential and pinion must be disassembled for inspection
of the front pinion bearing, which is lubricated by
oil from the automatic transmission.
472-6
SAAB
Page 549
32.
The pinion and its bearing housing are removed as
follows:
Undo the four screws securing the pinion bearing
housing and free the housing by tapping gently,
using a wooden drift to avoid damaging the surfaces.
ASSEMBLY
1.
2.
3.
4.
5.
6.
FIEMOVAL OF PINION BEARING
33.
Place the ring gear and the pinion bearing housing
in a press and use the press to separate the splines
of the ring gear hub and the pinion. The press drift
and its retainer 8790610 are introduced through
the hole in the ring gear hub so as to make contact
with the pinion. See illustration.
The following procedure should be used when pressing the ring gear hub and the pinion together. Lubricate the seal rings with automatic transmission
oil and ensure that they move freely in their grooves.
Slacken the two screws holding the seal housing and
hold the housing away from the seal rings, while
pressing the ring gear and the pinion together to
avoid damaging the seal rings.
Screw the seal housing to the pinion bearing housing using the two screws.
Fit the O-ring on the pinion housing.
Screw in the locating studs 8790222 and put on the
necessary number of shims. Locate the pinion housing and tighten the screws to the correct torque.
If the parking pawl previously has been removed,
fit parking pawl and spring and put in the shaft so
that the spring will be locked in the shaft groove.
Invert the transmission casing so that the underside
is uppermost.
Automatic transmission of earlier design: Check
that the seal rings on the ring gear turn freely in
their grooves. Lubricate the ring gear with automatic transmission oil and refit it. Fit the rear brake
band.
There are two types of rear brake band: One serrated and the other smooth. Note: The smooth
A. BRAKE BAND WITH SMOOTH SURFACE FOR REAR
DRUM
THE FOLLOWING DESIGNATIONS MAY OCCUR: 004 N,
3004 OR 1606
B. BRAKE BAND WITH THREE GROOVES FOR FRONT
DRUM
DESIGNATION: 005 K
SEPARATION OF RING GEAR AND PINION UNDER
PRESSURE
Drift 8790610
7.
SAAB
band is very similar to the front band but must
not be confused with it. (As from model 1976, the
front brake oand is serrated.) The smooth rear
band has "1606" stamped on the outside.
Place the shims, thrust bearing and thrust needle
bearing on the planet gear carrier. Grease the small
thrust bearing washer and the sun wheel rear thrust
needle bearing with vaseline and attach tehm to the
inside of the planet gear carrier. NOTE! The flange
on the small thrust bearing washer must point inwards the planet gear carrier.
472-7
Page 550
8.
Fit the planet gear carrier and centre support.
9.
Fit the front brake band. As from model 1976,
the front brake band is serrated.
4
S 2652
PL.ANET GEAR CARRIER WITH SHIMS AND THRUST
NEEDLE BEARING
1. Planet gear
2. Shims
3. Thrust bearing washer
4. Thrust bearing
FITTING THE FRONT BAND
10.
FITTING THE CENTRE SUPPORT
472-8
SUS
Place the thrust needle bearing between the two
sun wheels on the rear sun wheel shaft. Use Vaselin to keep the bearing in place. Check that the seal
rings are intact and move freely in their grooves.
Lubricate with automatic transmission oil. Carefully insert the shaft through the rear clutch, taking
care not to damage the seal rings.