Page 551
I
SHIMS, THRUST BEARING AND THRUST BEARING WASHER
Page 552
11.
14.
Locate the steel washer (with the two flat sides in
the hole) on the rear clutch hub. Mount the bronze
washer and the front clutch.
Place the long pressure rod against the rear band,
place the lever in position and insert the shaft from
side, at the same time holding the spring in place so
that the shaft engages. NOTE! One end of the
spring must lie against the lever throughout to
avoid scratching the cylinder.
S 2653
FITTING SHAFT AND SPRING FOR LEVER REAR BAND
REAR CLUTCH HUB WITH WASHERS, EARLIER DESIGN
15.
S2654
LOCATION OF THE WASHER ON REAR CLUTCH HUB,
EARLIER DESIGN
12.
13.
Insert the complete clutch assembly (front and rear
clutch) and fit the end plate. Check that the O-ring
is in place and intact. Check also the small O-ring on
the hub of the end plate.
Clean, inspect and if necessary exchange pistons and
piston seals. Lubricate the servo pistons and insert
in the servo cylinders.
472-10
.,.
a. Place the short pressure rod against the front
band, place the lever in position, and place the
automatic adjustment carrier against the front
band. Insert the shaft from the side through the
carrier and lever simultaneously. Adjust the
spring on the adjusting screw so that it lies 1.52 thread flights from the lever.
b. Make basic adjustment of front and rear band.
See section "Front band, adjustment" resp.
Rear band, adjustment".
Check the function of the automatic adjustment
by repeated operation of the servo for the front
brake band by means of compressed air. The adjusting screw should therewith be turned towards
the stop (when initially unadjusted). Poor functioning may be caused by the threads sticking or
insufficient force exerted by the adjusting spring.
Page 553
CHECKING THE AUTOMATIC ADJUSTMENT BY FORCING
COMPRESSED AIR THROUGH THE HOLE FOR APPLYING
THE SERVO
To ensure that the correct axial play is obtained in
subsequent measuring, the bearing in the torque converter housing should be tapped up to its lock ring.
(In transmissions of later design, the outer ring of
the bearing is accessible through two holes in the torque converter housing.)
FITTING TORQUE CONVERTER HOUSING
17.
16.
Place the gasket for the torque converter housing
in position. Mount the housing while simultaneously
fitting the contact washer onto the input shaft and
the three pipes inside the rear bottom cover. See
page 472-13.
The washer must be located between the bearing
and the step on the input shaft. Tighten the screws
to the specified torque. Fit the lower sprocket so
as to true up the shaft radially.
Mount the indicator dial and prize up under the
planet carrier with a screwdriver. The play should
be 0.01-0.03" (0.25-0.75 mm); if it is not within
these limits, adjust by shimming between the ring
gear and the forward sun gear, or between the washer and bearing on the input shaft.
NOTE
Do not tighten the sprocket wheel before checking
the play in the gear train.
MEASU-RING THE PLAY
SA.Ml
472-11
Page 554
18.
. 19.
Mount the torque converter and oil pump. This
must be done with great care to avoid damaging
the seal ring. Tap the pump housing with a plastic
mallet and tighten the screws.
Check that the pressure pipe from the pump to the
valve housing not have become deformed. Compare
the removed pipe with a new one.
Fit the two wide-bore oil pipes to the pump. Check
that the O-ring to the suction line is in place. Fit
the short pipe between the valve housing and torque
converter housing.
FITTING THE THROTTLE CABLE
OIL PIPE BETWEEN VALVE HOUSING AND OIL PUMP
20.
The suction line is secured by means of two clips
on later version transmissions.
Locate the valve housing and check that the pipes
engage the housing. Check that the manual gear selector is connected.
FITTING THE THROTTLE CABLE TO VALVE HOUSING
FITTING VALVE HOUSING
472-12
_,_
Page 555
~
21.
Secure the throttle valve wire and connect the inner
wire.
Tighten the three screws securing the valve housing.
22.
~-·-
23.
The following pipes are fitted on conjunction with step
16 (in the following order):
Return from the governor
No. 1
Main lubrication
No. 2
Rear clutch
No.3
These are located under the rear bottom cover.
0
0
Fit the remaining oil pipes in the following order:
Oil pipe for rear brake band (inner hole)
No. 4
Oil pipe for rear brake band (outer hole)
No. 5
Oil pipe for front brake band (application, "lower" hole in inverted transmission) No. 6
Oil pipe for front brake band (releasing,
"upper" hole in inverted transmission)
No. 7
Front clutch and governor
No. 8
Front lubrication
No. 9
Connect main lubrication from No. 2 to No. 10
Connect rear clutch from No. 3 to No. 11
Connect governor return line from No. 1 to No. 12
0
.........
::::::::
9 10 11 12
0
0
::::::::
0
0
0
;:::::::
"'"'
G
0
,._ __
-fO
2
1
0
8 7 6 5 4
3
S 3938
FITTING Oil PIPES
1. Return line from governor
2. Main lubrication
3. Rear clutch
4. Rear brake band, inner hole
5. Rear brake band, outer hole
6. Front brake band, application
"lower" hole (transmission
inverted)
7. Front brake band, releasing "upper"
hole (transmission inverted)
8. Front clutch and governor
9. Front lubrication
10. Main lubrication from 2
11. Rear clutch from 3
12. Return line·governor from 1
SAMS
472-13
Page 556
24.
Fit the chain and sprockets and tighten.
TIGHTENING THE SPROCKET, THE WHEELS ARE LOCKED
WITH TOOL 8790230
25.
26.
27.
Mount the pinion shaft, crown wheel and differential assembly with bearing housing.
Check the backlash adjustment, and readjust if necessary (see directions for assembly of pinion bearing).
Fit bottom covers and cowlings.
FRONT CLUTCH
Dismantling
1
2
4
6
5
7
8
9
10 11
12
•
FRONT CLUTCH DISASSEMBLED
1. Lock ring
2. Input shaft
3. Th rust washer
4.Hub
5. Discs
6. Spacer
472-14
wa
7. Lock ring
8. Return spring
9. Piston sealing
10. Piston
11. Sealing ring
12. Front clutch housing
rs2659
Page 557
1. Remove plate.
2. Remove lock ring from input shaft, saving the thrust
washer.
3. Lift out the forward clutch hub.
4. Remove clutch discs.
5. Remove lock ring for return spring and remove spring.
7. Check all seals and clutch discs for damage and wear,
replacing damaged parts. Do not forget the small O-ring
on the cylinder hub. Check the small leaf valve on the
back of the piston; spring movement should be 0.0200.039" (0.5-1.0 mm).
Assembling
1. Before beginning assembly, lubricate all components
with automatic transmission oil.
2. Fit O-ring to cylinder hub.
3. Insert piston using tool 8790107.
S 2660
REMOVING RETURN SPRING
S2662
6. Remove the piston with aid of compressed air.
INSERTING PISTON IN FRONT CLUTCH
Tool8790107
4. Check that steel ring on piston is properly seated.
5. Fit return spring with convex part downward on piston.
6. Fit pressure plate with flat side upward, checking that
outer plates are flat; if not, they must be exchanged
for new ones.
7. Place hub, clutch discs and thrust washer in position.
8. Check that the bushing on the input shaft is intact.
At the same time, check that the seal rings on the
shaft rotate freely in their grooves. If the rings stick,
check that the housing is not damaged.
9. Lay the input shaft in the clutch disc housing and fit
the lock ring.
REMOVING FRONT CLUTCH PISTON WITH THE AID OF
COMPRESSED AIR
SA.Ml
472-15
Page 558
REAR CLUTCH
Dismantling
9
i
J,6@
-,,c:=.1'\_
S 3901
REAR CLUTCH DISMANTLED
1. Rear clutch housing with
forward sun gear
2. Sealing ring
3. Piston
4. Piston sealing
5. Spring
6. Washer
7. Lock ring
8. Discs
9. Lock ring
The rear clutch is fitted with three lock ring grooves. The
center groove is used for the standard disc assembly. The
new disc assembly has a thicker pressure plate and one of
the steel discs has been removed.
1. Pull out forward sun gear shaft.
NOTE! Thrust bearings on both sides of gear.
2. Remove lock ring securing clutch discs.
3. Compress return spring using tool 8790081 in a press,
and remove the lock ring.
REMOVING REAR CLUTCH PISTON WITH THE AID OF
COMPRESSED AIR
Assembling
REMOVING LOCK RING FOR RETURN SPRING IN REAR
CLUTCH
Socket 8790081
4. Remove the piston with the aid of compressed air.
472-16
1. Check the needle bearing and bushing in the hub. Make
sure there are no scratches on the drum. If scratches
are found, the drum must be exchanged. Small blueannealed areas can be accepted.
Check that the cylinder is free from scratches. Check
all seals and clutch discs; If the clutch has been subjected to heat replace all the seals. Small scratches on
the pistons can be smoothed off with a fine cleaning
cloth. Check the small 0-rings on the clutch housing
hub. Small scratches on the piston can be smoothed
off with a fine cleaning cloth. Check the small 0-ring
on the clutch housing hub.
2. Insert the piston flat side downward using tool
8790099.
Page 559
2. Fit free wheel. NOTE! Flange on inner roller retainer·
faces outwards.
3. Insert centre support in the planet carrier and check
that it can be rotated clockwise.
S3900
SLEEVE 8790099
3. Place the return spring on the piston. If the spring has
been subjected to intensive heat it should be replaced.
4. Place the spring seat on the spring.
5. Compress the spring in a press with tool 8790081 and
fit the lock ring. See page 472-16.
6. NOTE! The outer clutch discs are cambered, and the
cambers must face the same way.
Begin assembly of clutch discs with an outer disc,
finishing with a spacer disc and pressure plate.
7. Fit lock ring.
NOTE
Th~re are two versions of the rear sun wheel and
the planet gear carrier and planet gear. The sun
wheel of one version and the planet gear carrier/
planet gear of the other version cannot be used together.
Identification grooves are used on the later version
to enable the two designs to be distinguished.
The rear sun wheel has a groove cut into the tops
of the cogs while the planet gear carrier has a groove
round its perimeter.
RING GEAR
111111
Exchanging
It may be necessary to exchange the ring gear if its male
teeth have been damaged, e.g. by misuse of the parking
pawl.
NOTE! If the ring gear has jammed on the pinion splines,
the latter can be removed together with the pinion bearing housing.
Remove lock ring and pull out shaft.
Reassemble in reverse order.
NOTE! Check that the seal rings rotate freely in their
grooves.
PLANET GEAR
Dismantling
i
0
S2666
PLANET GEAR WITH CENTRE SUPPORT AND FREE WHEEL
1. Centre support
2. Free wheel
3. Lock ring
4. Free wheel carrier
5. Thrust washer
6. Planet carrier
1. Pull out centre support from planet carrier and take
out free wheel.
2. Remove lock ring from planet carrier with a screwdriver and pull out free wheel carrier.
Assembling
CHANGING
1. Insert free wheel carrier and secure with lock ring.
SAMI
RING GEAR
472-17
,
.....,.
Page 560
7. Remove shaft seals with a screwdriver.
8. Tap the front race out gently with tool 8790214.
9. Tap out the rear race with tool 8790537 together
with drift 8390445.
PINION BEARINGS
Dismantling
When dismantling the pinion bearing the description "dismantling the transmission" will be followed until the pinion with its bearing housing has been removed. Then the
dismantling continued as follow below.
Assembling
1. Undo the two screws securing the seal housing over
the pinion nut.
2. Fit the pinion housing to fixture 8790636 and its associated retainer ring 8790651.
3. Remove O-ring.
4. Clamp tool in a vice and unscrew pinion nut.
1. Fit the two shaft seals in the housing using tool
8790164, see fig. Fit outer bearing rings.
UNSCREWING THE PINION NUT
Fixture 8790636, retainer ring 8790651, sleeve 8790263
S 3206
LOCATION OF PINION BEARING SHAFT SEALS
IN THE BEARING HOUSING
5. Withdraw pinion from bearing housing.
6. Press off the rear pinion bearing. Use the fixture and
the retainer ring as a support (see point 2).
2. Press rear pinion bearing onto the shaft. Fixture
8790636 and press ring 8790644 are used as a support.
PRESSING OFF THE REAR PINION BEARING
PRESSING ON THE REAR PINION BEARING
Support, fixture 8790636, retainer ring 8790651
Support, fixture 8790636, ring 8790644
472-18
SAAB