Page 661
REMOVAL
Clean the area around the hydraulic connections before
disconnecting them.
1. Siphon the oil out of the reservoir.
2. Loosen the servo pump and lift it away from its
mounting so that the double joint and servo valve
become accessible.
3. Block up the engine and remove the left-hand engine mounting.
4. Turn the steering wheel to full left lock and remove
the clamp screw which holds the dubble joint on
the intermediate shaft to the steering gear.
5. Remove the pipe clamps at the front suspension
panel.
6. Jack up the car and remove the front wheels.
7. Undo the tie-rod ends at the steering arm by means
of tool 8995409. Unscrew the left-hand tie-rod end.
8. Disconnect the speedometer cable from the gear box
and disconnect the left-hand handQrake cable at the
brake yoke and wheel housing. Rem.ove the righthand handbrake cable clamp on the steering gear.
9. Undo the steering gear mounting to the body.
Left-hand side: Remove the two retaining bolts and
remove the intermediate piece.
Right-hand side: Remove the yoke and intermediate
piece.
10. Disconnect the delivery and return lines from the
servo valve.
11. Pull the steering gear downwards and slightly to the
right so releasing the intermediate shaft.
11. Move the steering gear to the right until the lefthand tie rod can be bent down through the opening
in the body (see the picture), at the same time,
twisting the valve housing backwards.
BEND THE LEFT TIE ROD DOWN THROUGH THE OPENING
IN THE BODY
12.
Remove the steering gear by guiding it down and
to the left.
REMOVING THE STEERING GEAR FROM THE CAR
INSTALLATION
Clean the hydraulic fluid container and pipes before fitting a new or reconditioned steering gear.
It may also be necessary to remove the servo pump and
flush it with hydraulic fluid.
During the installation of the power steering gear, the left
SAAB
644-3
Page 662
I
j
1.
tie-rod end assembly should be removed and the rack
should be moved all the way over to the right.
2.
3.
IMPORTANT
When the end piece is loosened and tightened, the
torque in the rack must not be taken up by the
pinion.
The rack must r.ot be clamped in the servo end.
Clamp the rack in the toothed end with suitable
soft jaws (wooden blocks).
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=4
"""'
STEERING GEAR READY FOR INSTALLATION
Move the steering gear up to the right through the
bottom opening in the body with the valve housing pointing backwards. Turn the valve housing
upwards through the body opening and lift the
steering gear over to the right so that the left tie
rod can be bent up.
2. Put the steering gear in place and make sure that
the speedometer cable and the handbrake cables
are in the right position.
3. Fit the intermediate shaft to the steering gear splines. Ensure that the clamp screw is correctly fitted
in the groove at the end of the shaft.
4. Fit the intermediate pieces, yoke and bolts and
tighten the steering gear.
5. Connect the speedometer cable and the left-hand
handbrake cable and secure the right-hand handbrake cable to the steering gear by means of a plastic clip.
6. Attach the left tie-rod end assembly and attach the
end assemblies to the steering arms with new lock
nuts'.
7. Mount the wheels and jack down the car.
8. Clamp the pipe to the front suspension panel.
4.
1.
9.
10.
11.
12.
13.
14.
Mount the steering bearing bracket to the body
and install the rubber bellows at the dash panel
opening.
Fit the trim panel below the instrument panel.
Fit the engine mounting.
Install the servo pump.
Adjust the toe-in and, if necessary, the steering
wheel.
Fill the servo unit with oil (see group 1).
DISASSEMBLY
Before disassembly, wash the steering gear thoroughly
on the outside. When working on the servo-assisted steering gear, cleanliness is of the utmost importance. Be especially careful of the servo valve and the sealing surfaces
on the rack.
644-4
Back off the lock nut and remove the tie-rod end
assemblies.
Loosen the clamps and take off the rubber bellows.
Bend up the lock plate between the end piece and
the rack.
Clamp the toothed end of the rack in a vice between two wooden blocks and unscrew the end
pieces. Set the spring and washer aside.
THE END PIECES ARE REMOVED FROM THE RACK
Tool8995995
5.
6.
7.
8.
Undo the lock nut for the radial adjustment of
the rack and undo the adjusting screw. Remove
the adjusting screw retaining plate, the spring,
the O-ring and the plunger.
Remove the tubes between the servo valve and
the two sides of the servo cylinder.
Undo the three lock nuts and detach the valve
housing and servo valve with pinion. Keep the
servo valve in a clean plastic bag.
Remove the locking screw for the ring nut with
a hexagon wrench.
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Page 663
11.
Pull the rack out of the steering gear housing. Remove the knurled sleeve, the servo seal and the
washer from the cylinder. Remove the plunger
seal and snap ring.
NOTE
The plunger cannot be detached from the rack.
12.
S"'32
REMOVING THE RING NUT LOCKING SCREW
9.
If the pin ions needle bearing shows ~igns of wear,
it should be removed into the steering gear housing.
Inspect and replace damaged components. Replace
all seals, lock plates and gaskets between the valve
housing and the steering gear housing. The rubber
bellows should also be replaced.
ASSEMBLY
Clamp the steering gear end in a vice and remove
the ring nut with C spanner 8995961.
LUBRICATION IN CONNECTION WITH ASSEMBLY
Oil the hydraulic components of the steering gear with
hydraulic oil.
Oil the rack, pinion and other bearings with lubricating
oil (according to API Service G L4 SAE 75 or SAE
80-90). Topping up, see pos. 12.
Lubricate the inner ball joints if disassebled with molybdenum paste (part No. (45) 3006 632
1.
2.
REMOVING THE RING NUT
Tool 8995961
10.
Apply Loctite to the needle bearing seat and push
in the needle bearing, if it has been removed.
a. Fit the snap ring and new teflon ring on the
rack plunger.
b. Slide the knurled sleeve onto the rack.
c. Fit the servo seal on the fitting sleeve using
the cone. (Special tools 8995938 and 8995946).
Slide the sleeve with seal past the teeth on the
rack. Remove the tool. Turn the notch in the
seal towards the servo plunger.
Remove the steering gear end from the cylinder
and the rack while removing the bleeder tube.
Set aside the loose cone in the hole for the oil
tube. Remove the sealing ring, washer and servo
seal from the steering gear end.
S"'35
SLIDE THE SERVO SEAL ONTO THE FITTING SLEEVE
USING THE FITTING CONE (SPECIAL TOOLS 8995938
AND 8995946)
""'
REMOVING THE STEERING GEAR END FROM THE
CYLINDER
SAMI
644-5
Page 664
4.
Fit the steering gear end as follows:
a. Fit the servo seal in its seat. Turn notch in the
seal towards the servo plunger.
b. Put on the washer. Turn the smaller diameter
of the washer towards the servo seal.
c. Fit the seal with the square profile.
d. Put the cone into the tube connection hole and
lock the cone using special tool 8995953. The
cylindrical part of the cone (inside the steering
gear end) serves to fix the po:.ition of the steering gear end in relation to the servo cylinder.
SLIDE THE FITTING SLEEVE 8995946 WITH SEAL PAST
THE TEETH ON THE RACK
d. Slide the washer onto the rack.
54037
S4039
PUSH THE RACK WITH WASHER, SERVO SEAL, SLEEVE
AND PLUNGER SEALS INTO THE SERVO CYLINDER
3.
LOCKING THE CONE IN PLACE WITH A SPECIAL SCREW
Tool 8995953
e. Screw fitting cone 8995987 onto the rack end
and fit the steering gear end onto the rack and
servo cylinder while inserting the vent tube. The
cylindrical portion of the cone fits into the Ushaped recess in the end of the servo cylinder.
Tighten the ring nut with a torque wrench connected to special tool 8995961 with a torque of
120-125 ft.lb. ( 16.5-17 .5 kpm, 165-175 Nm),
corresponding to a torque of 130-135 ft.lb.
(18-19 kpm, 180-190 Nm) at the nut. Lock
the nut with the socket head screw.
Push the rack into the servo cylinder until the
knurled sleeve can be seen in the hole for the tube
connection. Use a screwdriver to turn the sleeve
to expose its threaded hole. Screw in the connecting screw temporarily to hold the washer in place.
(Do not tighten the screw all the way or the rack
may be damaged.)
S4038
TURN UP THE HOLE IN THE KNURLED SLEEVE
644-6
S4040
FITTING THE STEERING GEAR END. THE RACK END IS
FITTED WITH FITTING CONE 8995987
SA1'B
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Page 665
5.
6.
Fit the washer and the seal between the pinion and
the servo valve in the steering gear housing.
Fit the servo valve in the gear housing.
RADIAL ADJUSTMENT OF THE RACK
9.
10.
S4041
FITTING THE SERVO VALVE
7.
Fit the gasket (earlier design) or the O-ring (later
design) between the valve housing and the steering
gear housing. Fit the sealing ring, dust protection
and lock ring in the valve housing. Apply silicone
grease between the seal and the dust protection.
Place the fitting tool 8995979 over the shaft end
of the valve. Fit the valve housing. Tighten the
lock nuts with a torque of 16.6 ft.lb. (2.3 kpm, 23
Nm).
11.
Fit plunger, O-ring, spring, cover, adjusting screw
and lock nut for the radial adjustment of the rack.
Clamp the toothed end of the rack in a vice between two wooden blocks and fit the complete
end pieces with thrust washer, spring and lock
washer. Tighten the end piece with a torque wrench
connected to tool 8995995 to 42.6-59.1 ft.lb.
(5.9-6.8 kpm, 59-68 Nm), corresponding to a
torque of 47.0-54.2 ft.lb. (6.5-7.5 kpm, 65-75
Nm) at the end piece. Check the play in the inner
ball joint and adjust if necessary. See "adjustment
of inner ball joint".
Lock the shim.
Adjust the radial play of the rack as follows:
a. Screw in the adjusting screw all the way until
the resistance of the twisting steering gear is
felt.
b. Back off the adjusting screw 1/12 turn.
c. Check that the steering gear can be turned from
lock to lock in both directions without jamming.
d. Tighten the lock nut with a torque of 50-60
ft.lb. (7.0-8.3 kpm, 70-83 Nm).
5404'
FITTING THE VALVE HOUSING. THE VALVE SHAFT IS'""'
FITTED WITH FITTING CONE 8995979
ADJUSTING THE RADIAL PLAY OF THE RACK
12.
8.
Remove tool 8995953 from the connection hole
in the steering gear end. Fit the tubes between the
servo valve and the two sides of the cylinder. Fit
new gasket on the banjo connection of the shorter
tube to the cylinder.
13.
WEI
Fit the rubber bellows. Fit all clamps except one at
one of the tie rods. Hold the steering gear vertical
and using an oil can, inject 6.5 fl.oz. (0.19 dm 3 ,
1.9dl (as per API serviceGL4,SAE75orSAE8090) between the bellows and tie rod. Fit the clamp.
Fit lock nuts and tie-rod end assemblies.
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Page 666
CHECKING THE INNER BALL JOINT (IN SITU)
3. Clean and check the parts.
The play in the inner ball joint should be checked when
setting the front wheel alignment, in the event of noise
from the front suspension or if a fault is suspected.
Oscillate the wheel towards and away from the body
of the car while it is standing on the floor.
i
)
I
11
S 7507
B
Max. permissible play 1 .0 mm
(Noise is audible at 0.1-0.2 mm play).
WEAR LIMITS FOR REPLACEMENT OF TIE-ROD
A. Wear limit 3 mm
8. Max. permissible amount of shims for adjustment - 2 mm.
A vernier gauge on a magnetic attachment should be
used for more exact measurements. Attach the gauge
above the tie-rod end with the point against the wheel
housing. Raise the front suspension unit so that the
tie-rod is aligned with the rack.
NOTE
It may be necessary to replace the tie-rod assembly
if grooves are worn in the surfaces of the ball and/
or cups. After adjustment the tie-rod should move
freely in all angles.
INNER BALL JOINT ADJUSTMENT (STEERING GEAR
REMOVED AND DISMANTLED)
1. Bend back the tab washer at the end piece.
2. Clamp the end piece in a vice and remove the outer
ball cup using tool 8995995 and a puller.
CAUTION
Do not clamp the outer ball cup in a vice as this can
deform it.
S 7506
4. Assemble and adjust the end piece:
a. Apply molybdenum paste (part no. (45) 30 06 632)
to the ball and cups.
b. Assemble the end piece using new shims and a new
tab washer. Insert the shims so that there is no play
in the steering joints and that they do not seize in
any angle once the nut and outer ball cup have
been tightened to the prescribed torque.
ITorque
69-88 ft. lb. (95-122 Nm (9.5-12.2 kpm})
Check: Tighten the tie-rod end. Hold the end piece at
right angles. It should be possible to place the tie-rod in
all positions and drop it to facilitate applying pressure to
the tie-rod end. Over-tightening can rupture the tie-rod.
644-8
SAAB
Page 667
SERVO PUMP
Removal
1. Suck the oil out of the oil tank.
2. Drain the coolant through the drain cock on the engine block and disconnect the hose from between the
expansion tank and the water pump.
3. Disconnect the suction hose and delivery line from
the pump. Grip the hexagonal nipple on the pump
when removing the delivery line.
4. Unbolt the pump unit from the bracket and engine
mounting. Lift off the V-belt and remove the pump
complete with mounting.
MOUNTING POSITION FOR PUMP IN LINE WITH DELIVERY
LINE CONNECTION
b. Slide the pump mounting so that the distance berween the lower lug on the mounting and the centre of the pulley is 1.93 ± 0.02 in. (49 ± 0.5 mml.
REMOVING THE SERVO PUMP
5. Dismantle the pulley and pump mounting from the
pump.
CAUTION
Never knock the pulley off the shaft as this may damage the pump. If necessary, use a press or extractor.
Assembly
1. Mount the pump mounting to the pump without completely tightening the screw.
2. Mount the pulley and key and tighten the pulley bolt.
CAUTION
Never knock the pulley onto the shaft as this may
damage the pump. Slide the pulley onto the shaft
by tightening the bolt.
3. Adjust the position of the pump mounting on the
pump as follows:
a. Twist the pump mounting so that the clamp tightening screw is aligned with the delivery line connection.
DISTANCE BETWEEN PUMP MOUNTING AND PULLEY
CENTRE
c. Tighten the pump mounting.
4. Mount the pump unit to the engine mounting and the
bracket. Fit the V-belt and adjust the tension. Check
that the V-belt is clear of the alternator belt and engine.
5. Connect the delivery line and suction hose to the pump.
6. Connect the coolant hose and refill with coolant.
7. Fill the tank with oil. Start the engine and then top up
to a level about 0.4 in. (1 cm) above the bottom of the
filter.
Bleed the system by turning the steering wheel from
lock to lock two or three times.
CAUTION
Never keep the steering wheel at full lock by force
at the same time as the engine is running as this can
give rise to overheating of the servo pump and subsequent damage.
644-9
Page 669
CONTENTS
700
GENERAL
731
COIL SPRING SUSPENSION, FRONT
732
COIL SPRING SUSPENSION, REAR
761
SHOCK ABSORBERS
771
WHEELS
774
HUBS
SI\AB