Page 571
3.
4.
Lift up the valve housing. Guide both the pipes
into their respective holes in the valve housing.
The pipes must go freely into the valve housing.
If force is used during assembly, the pressure pipe
Nill be deformed.
.,..ighten the three retaining screws.
8.
Start with pipe No. 4. It is necessary to feel around
for the hole in the transmission housing, as it is difficult to remove the side cover with the transmission in the car.
PIPE NO. 4 IS INSTALLED
SCREWING ON THE VALVE HOUSING
9.
5.
Then fit pipe No. 5, which must not be confused
with pipe No. 11, in the valve housing.
Check with the help of a small mirror that the
pipes are in place.
THE PIPE CONNECTIONS ARE CHECKED WITH THE AID
OF A MIRROR
PIPE NO. 5 IS INSTALLED
6.
10.
7.
Fit the throttle cable and make sure that it is .;orrectly placed on the blade wheel.
Then continue with the fitting of the pipes. Various
problems can arise, and we therefore suggest that
you refer to the diagram in the Service Manual
(page 472-13), which can be of great help.
11.
If the diagram is followed the remaining pipes
should not present any difficulty in fitting.
Do not forget to place the Iittre magnet above
pipes No. 11 and 12.
472-29
Page 572
15.
16.
17.
Screw on the guard plate.
Fill with oil to correct level.
Adjust the oil pressure with the throttle cable.
CHANGING THE REAR CLUTCH AND FRONT BRAKE
BAND
Dismantling
1.
THE MAGNET IS PUT IN PLACE
2.
3.
4.
12.
Secure the filter to the suction pipe.
5.
6.
7.
8.
9.
10.
Lift out the power plant, place it on a trestle and
drain the transmission oil.
Wash the power plant.
Remove the ring gear cover, the front cover and the
two large covers at the bottom of the transmission.
Remove the oil pipes and valve housing (see special
section).
Remove the sprockets and chain.
Remove the four bolts securing the torque converter to the driver disc.
Remove the torque converter housing retaining
bolts and lift the housing and torque converter
away from the engine.
Remove the driver disc from the crankshaft.
Lift out the front clutch and front drum with the
rear clutch from the transmission housing.
Remove the front band from the transmission
housing.
For clutch overhaul refer to special section.
Assembly
THE FIL TEA IS SECURED TO THE SUCTION PIPE
1.
2.
13.
14.
Check that the bottom cover is not deformed at
the screw holes. If such is the case it must be
straightened.
Fit the bottom cover with a new gasket without
adhesive.
3.
4.
5.
6.
7.
THE BOTTOM COVER IS INSTALLED
472-30
Mount the front band in position in the transmission housing.
Place the needle bearing washer and needle bearing
in the planet gear carrier, keeping them in place by
means of Vaseline.
Install the sun gear shaft and front drum as one
unit.
Keep the axial washers in place on the front drum
hub by means of Vaseline.
Install the front clutch assembly with input shaft
in the transmission.
Fit the front cover.
Check and adjust the front and rear bands. (See
special section.)
Page 573
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Mount the driver disc on the crankshaft. Coat the
threads with Loctite sealant 68 or an equivalent
sealing agent.
Install the torque converter housing and the torque
converter.
Measure the axial play in the transmission. Make
any necessary adjustments by means of the front
axial washers.
Mount the torque converter on the driver disc.
Fit the suction and pressure pipes, valve housing,
oil pipes, filter and magnet in the transmission.
(See special description.)
Fit the bottom covers.
Install the primary gear sprockets, chain and the
front cover.
Fit the cover over the ring gear.
Fill the automatic transmission with oil.
Install the power plant in the car.
472-31
Page 575
DIFFERENTIAL AND PINIONCROWN WHEEL GEAR
Before measuring
GENERAL
The crown wheel and pinion are a matched pair, so if one
is exchanged the other must be exchanged too. The parts
are tested together for noise and the optimum setting for
minimum noise output is measured. The key measurements as far as the pinion and crown wheel are concerned
are firstly the distance from the end face of the pinion to
the center of the crown wheel, and secondly the backlash
between the teeth. These measurements and the mating
number are stamped into both parts at the time of noise
testing. When the pinion and crown wheel are installed,
these measurements must be accurately adjusted with
shims and a special measuring instrument. The pinion gear
shims are placed next to the bearing housing of the pinion
shaft bearings, and the crown wheel (differential) shims
are distributed between the two differential bearing seats.
ADJUSTING THE POSITION OF THE PINION GEAR
General
Data for adjustment of the distance from the pinion gear
to the center of the crown wheel are stamped into the
end face of the pinion (an example is illustrated below).
The following preparations must be made prior to measuring the pinion gear setting:
The following applies to manual transmissions: The pinion shaft bearings must be compressed until the torque
required to rotate the pinion shaft in the housing is 2.5
± 0.5 Nm (25 ± 5 kpcm), corresponding to a dynamometer reading of 47-71 N (10.4-15.4 lb., 4.7-7.0 kp). These
figures apply to new, lightly oiled bearings. The corresponding figures for older bearings (which have done more than
1,200 miles (2,000 km) are 1.3 ± 0.5 Nm (13 ± 5 kpcm),
the dynamometer readings being 19-43 N (4.2-9.5 lb.,
1.9-4.3 kp).
In the case of automatic transmissions the following is
applicable:
The pinion shaft nut must be tightened to 245-265 Nm
(180-200 ft.lb., 25-27 kpm). The torque required to
rotate the pinion shaft in the housing must be 1.8-3.0
Nm (16-26 in.lb., 18-30 kpcm), corresponding toadynamometer reading of 27-46 N (5.9-10.1 lb., 2.7-4.6
kp). These figures refer to new, lightly oiled bearings.
For bearings that have done more than 1,200 miles (2,000
km) the torque should be 0.9-1.5 Nm (8-13 in.lb., 9-15
kpcm), corresponding to a dynamometer reading of 1524 N (3.3-5.3 lb., 1.5-2.4 kp).
The differential unit must be removed to permit installation of the measuring instrument (tool 8390155), which
consists of a measuring jig with attached indicator dial.
A ground gauge block is provided for calibration of the
END FACE OF PINION
+3
R 913
0
measurement for pinion setting
mating number, also stamped on crown wheel
pinion not offset - shaft centerline intersects
crown wheel centerline (all pinions are marked
0 and this datum has no relevance to the adjustment)
CALIBRATING
THE INSTRUMENT
DIAL
Measuring instrument 8390155
dial; the block is laid against the calibration stops of the
instrument, and the distance between these stops and the
centerline of the tool is exactly 2.362" (60.000 mm),
equal to the distance from the end face of the pinion
shaft to the center of the crown wheel (see illustration).
The procedure for measuring the pinion gear position is
as follows:
IMPORTANT
Before disassembling the transmission, always measure the positions of the pinion and crown wheel.
This provides a check on whether the setting may
have been wrong. If the pinion shaft and crown
wheel assembly has done less than 6,000 miles
(10,000 km), the setting can be adjusted, but after
longer mileage, when the gears will have worn themselves into a certain position, the parts should be
reassembled with the same settings as were measured prior to disassembly.
Measuring
1. Check that the pointers of the instrument are zeroed
when the measuring point touches the gauge block (see
illustration).
SAAB
473-1
lflfll
Il
W,W
Page 576
2. Place the instrument in he differential housing with
the point applied to th flat end of the pinion gear and
take a reading (see illus ration).
1
s 1845
ADJUSTING THE PINION GEAR, MANUAL TRANSMISSION
1.Shim
2. Roller bearing
3. Bearing housing
4. Pinion
MEASURING TOOL LOCA
OPENINGS, MANUAL TRA
DIN DIFFERENTIAL
BEARING
SHIM TABLE, MANUAL TRANSMISSION
3. When the pinion gear is correctly positioned, the dial
should show the number of hundredths of a millimeter
(+or-)
stamped into the pinion with a permitted
tolerance of± 0.05 mm.
Location
Pinion shaft between
bearing housing and
transmission case
MEASURING TOOL LOCATED IN AUTOMATIC
MISSION
0.10
0.15
0.30
0.50
8341752
8341760
8341778
8344723
ADJUSTING THE PINION GEAR, AUTOMATIC TRANSMISSION
TRANS-
1. Shims
2. Roller bearing
3. Bearing housing
4. Pinion gear
Shimming
If the measured reading is outside the permitted tolerance,
the pinion shaft must be adjusted. This is done with shims
placed between the pinion shaft bearing housing and the
transmission case (see illustration).
473-2
Shims
Thickness mm
Spare part No.
SAMl
Page 577
SHIM TABLE, AUTOMATIC TRANSMISSION
Location
Pinion shaft between
bearing housing and
transmission case
Rechecking
Shims
Thickness mm Spare part No.
0.10
0.15
0.30
8707481
8707499
8707507
After shimming, replace the measuring jig in the differential housing and check that the dial now gives the correct reading to within ± 0.05 mm. If it does not, the
shimming procedure must be gone through again.
Procedure for shimming is as follows:
1. Undo the four screws from the pinion shaft bearing
housing and tap the pinion shaft gently out of the
transmission case.
2. Change the shimming according to the following
rules:
a) If the dial reading is higher than the correct value,
increase the shim combination.
b) If the dial reading is lower than the correct value,
reduce the shim combination.
NOTE! + reads counter-clockwise and - reads clockwise on the dial.
Reduce or increase the shim combination by the difference between the measured and correct values.
\
If the pinion is stamped +3, the pointers should indicate
+0.03 mm. A deviation of± 0.05 mm from this reading
is permitted.
Checking the measuringjig
The measuring jig is a precision-made tool. It should be
handled with care to avoid knocks and deformation. If
there is reason to suspect that the jig may have been damaged in such a way that it gives wrong readings, it can be
measured as a check. The dimension indicated in the illustration on the right should be measure.d for this purpose.
If the pinion is stamped -7, the pointers should indicate
-0.07 mm. A deviation of ± 0.05 mm from this reading
is permitted.
3. Having selected the correct combination of shims,
place them in the transmission case with aid of the
locating pins. Mount the pinion shaft to the transmission case using sleeve 8390148 and arbor 8390114.
Remove the locating pins and tighten the screws to
the prescribed torque and lock them with Loctite.
S 1847
CHECKING THE MEASURING JIG
SAAB
473-3
Page 578
ADJUSTING CROWN W EEL BACKLASH, MANUAL
AND AUTOMATIC TRA SMISSION
MEASURING AND SHIMMING, AUTOMATIC AND
MANUAL TRANSMISSION
Certain data for adjustme t of crown wheel backlash are
stamped into the crown w eel as illustrated below.
Adjustment of differential bearings
CAUTION
Adjustment must be carried out before the pinion
shaft is mounted. ( If only the final drive has been
dismantled for the replacement of the differential
bearings, the crown wheel must also be dismantled
before the bearings can be adjusted.)
1. Place the differential assembly complete with crown
wheel in the transmission case.
2. Mount the left bearing seat (the one with the speedometer drive) without shims and tighten the screws to
the prescribed torque of 20-25 Nm (14-18 ft.lb.,
2.0-2.5 kpm).
3. Oil the differential bearings and mount the right bearing seat. If the inner driver is mounted in the bearing
seat, remove the spring and plunger before mounting
the seat. Tighten the screws, in two or three stages,
with a torque of about 2.2 Nm (19 in.lb., 22 kpcm).
Rotate the differential while tightening the screws.
S 4568
CROWN WHEEL MARKING
870488
9:35
73-04
02
-17
1330
Part number ( ot article number)
Ratio
Date of manu acture
Material code
Backlash of O 17 mm
Mating numb r which is also stamped on the
pinion
The backlash should be checked at four points round the
circumference of the cro, vn wheel and must not deviate
by more than ± 0.05 mm from the stated measurement.
Crown wheel backlash is ~djusted with shims. Up to four
shims may be used in sui1~ble combinations.
TABLE SHIMS
Shims
hickness mm
Spare part No
Between differential bearing seat and
transmission case
I
473-4
0.10
0.15
0.30
0.50
TIGHTENING
8341604
8341612
8341620
8341638
THE RIGHT BEARING SEAT
4. Measure the gap between the transmission case and
bearing seat with a feeler gauge at two points opposite
each other and take an average of the two measurements. Then select shims corresponding to this result
plus an increment of 0.20 mm to obtain the correct
bearing compression.
SN\El
Page 579
NOTE
The resulting set of shims should then be distributed
between the right and left sides to give the correct
gear backlash.
ADJUSTING CROWN WHEEL GEAR BACKLASH
MEASURING
BEARING SEAT GAP
NOTE
The method described above applies to both new
and old bearings.
1. Place the differential assembly complete with crown
wheel in the transmission case.
2. Mount the left bearing seat (the one with the speedometer drive) without shims and the right bearing seat
with the selected set of shims, tightening the screws
to the prescribed torque of 20-25 Nm ( 14-18 ft.lb.,
2.0-2.5 kpm).
3. Mount the indicator dial, see illustration, and measure
the gear backlash.
4. Calculate the difference between the measured backlash and the desired gear backlash, and then move
shims of suitable thickness over to the left bearing
seat. Measure again afterwards as a check.
The torque obtained in this way can be measured by
means of a torque wrench and driver 8790818.
MEASURING THE DIFFERENTIAL
BEARING TORQUE
MEASURING GEAR BACKLASH,
MANUAL
TRANSMISSION
Torque wrench and driver 8790818
Ensure that you adjust to the correct values. The following values apply for the rolling torque:
New, lightly oiled bearings 1.8-2.8 Nm (16-24 in.lb.,
18-28 kpcm).
Bearings having run more than 1.200 miles (2.000 km)
0.8-1.3 Nm (7-11 in.lb., 8-13 kpcm).
Shims of four different thicknesses can be suitably combined. The available thicknesses are shown in the table
below.
TABLE SHIMS, MANUAL
Location
Between differential bearing seat and
transmission case
AND AUTOMATIC
TRANSMISSION
Shims
Thickness mm Spare parts No
0.10
0.15
0.30
0.50
8341604
8341612
8341620
8341638
MEASURING
MISSION
GEAR BACKLASH, AUTOMATIC
TRANS-
473-5
Page 580
Assembling
The preselected set of s ims must be used for adjusting the backlash. T total thickness of the set
must not be altered.
DIFFERENTIAL, MANU
TRANSMISSION
IMPORTANT
If the crown wheel is exchanged, the pinion gear
must be exchanged with it, as these two parts are
individually matched.
LAND AUTOMATIC
1. Exchange worn or damaged parts.
2. Locate the gears and wear washers if any in the differential casing and slide in the differential drive shaft.
Removing
To replace parts inside th differential, remove one of
the lock rings on the diffe ential drive shaft. The shaft,
drive and wear washers ca be removed without the differential having to be dis antled.
1. Remove the differentia housing cover.
2. Remove tlie two differ ntial bearing seats together
with inner drivers. Sav any shims and remove the differential.
3. If necessary, press the uter bearing rings out of the
bearing seats (see Dism ntling of the inner driver with
differential bearing ca . Remove the speedometer
drive and press both jo rnal bearings off the differential housing using tools 89 95 185, 87 90 768 and
8995177.
WEAR WASHERS
3. Mount the crown wheel and tighten the screws to 50
Nm (36 ft.lb., 5.0 kpm). Use locking fluid for the
crown wheel screws.
REMOVING DIFFERENT!
L JOURNAL BEARINGS
4. Remove the crown wh el screws and take off the
crown wheel.
5. Push out the different al gear shaft.
6. Remove the gears and he wear washers from the differential casing and ta e the springs out of the gears.
473-6
4. Press on the journal bearings and the speedometer
drive, if these have been previously removed, using
tool 8790487.
SA-S
•