Page 701
ALIGNMENT JIG FOR ACCIDENT-DAMAGED BODIES
Trueing-up tool
An alignment jig with trueing-up tools and accessories to
fit both Saab 95/96 and Saab 99 cars has been designed
to facilitate the repair of car bodies damaged in road accidents.
There are two types of alignment jigs, an earlier version,
and a later and more up-to-date version.
The trueing-up tool is used to straighten out deformed
portions of the car body. It consists of a lever which is
secured at the bottom by a chain to two of the legs of
the alignment jig. A hydraulic pressure cylinder is attached to the middle of the lever, and a draw chain is
attached to the top. This arrangement makes the tool
compact (and easily portable) and also allows the direction of pull to be varied within very wide limits. Neither
the alignment jig nor the trueing-up tool need be anchored to the floor.
Before the trueing-up tool is used it is mounted on the
alignment jig in the following manner:
1. Select the desired direction of pull, first laterally by
positioning the trueing-up tool accordingly, and then
vertically by attaching the draw chain at a suitable
height on the lever.
2. Secure the trueing-up tool to the alignment jig by
fastening both ends of the anchor chain to two of
the legs of the jig in such a way that tension will be
applied to both halves of the chain.
3. Place the pressure cylinder against the pressure beam
and alignment jig, first locating it laterally with respect to the jig so that the cylinder comes just about
vertically below the draw chain. Then adjust the vertical position of the cylinder on the lever so that the
lines of the draw chain and pressure cylinder, if extended, will intersect at the same point on the floor
or will be almost parallel (see illustration).
4. Adjust chain lengths as necessary, prize apart the quickrelease extension of the pressure cylinder, and wrap
the safety chain one turn around the beam of the
alignment jig.
Alignment jig
The alignment jig consists of a rigidly constructed frame
with plane surfaces containing a series of precision-drilled
holes. Fixtures for accurate location of body parts can be
screwed into these holes. Special checking fixtures are
also provided; these are placed on top of the locating fixtures. When the car is set up on the alignment jig, it is possible with the help of the checking fixtures to measure
any deformation of the chassis attachment points without
having to remove parts of the chassis.
The alignment jig is provided with a pair of wheels to
make it mobile. It need not be secured to the floor, but
when in use it should be placed on a level surface with
the wheels removed.
Application of trueing-up tool
ALIGNMENT
The draw chain and hydraulic cylinder must be placed so
that the extended lines drawn through them intersect at
the same point on the floor or are nearly parallel. There
are then no free forces tending to lift the tool or the alignment jig.
JIG
54088
APPLICATION
OF TRU El NG-UP TOOL
SAAB
810-2
Page 702
Description of alignment jig and trueing-up tool
A description of the alignment jig and accessories and
trueing-up tool is available and can be ordered from
Saab-Scania in Nykoping under the ordering number
101733.
TRUE ING-UP TOOL
1. Draw chain
2. Anchor chain
3. Pressure cylinder
4. Lever
5. Pressure beam
6. Hand pump
Hoisting gear, etc.
Before the alignment jig can be used, the car body or
complete car must be lifted on to it. The best method
is to use a fork-lift trolley or overhead traveling crane.
If these are not available, the job can be done with a
high-lift garage jack and a mobile collapsible trestle set
consisting of four legs on wheels and two cross-pieces.
The trestles can also be used for assembly and disassembly
work 0!1 chassis, etc. and for blocking up and moving cars
with the wheels off.
The procedure for mounting the car body on the jig is as
follows:
Place the cross-piece on the jack and then push the latter
under the car from the side at the rear edge of the threshold. Raise the rear of the car so that the legs can be fitted
to the cross-piece. Then repeat the same procedure at the
front. The car can then be maneuvered over the jig with
the trestle legs straddling the jig and lowered into position
with the jack.
A suitable bench or platform about 450-600 mm ( 1 1/22 ft.) high should be available for work on the roof of the
car or upper parts of the body.
810-3
&AMI
Page 703
Alignment jig, later version
The alignment jig of the later version has the same clamp
sets as the earlier jig, but is lower, providing a more favourable working height and simplifying mounting. The draw
aligner is secured directly to the jig, which makes it easier
to work with.
The jig is mounted on 4 castors and is designed to stand
on these even during the aligning work.
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of a forked bracket and a locking pin. It is of the utmost
importance that this always be locked securely during operation of the draw aligner.
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DRAW ALIGNER, LATER VERSION
S66T.
ALIGNMENT
JIG
Draw aligner, later version
The Caroliner draw aligner, in a version designed specially
for this alignment jig, is equipped with a hydraulic cylinder which can apply a load of ten tons. The draw aligner is
mounted on castors and can be secured at any point
round the frame of the jig. It is secured to the jig by means
EXTENSION PIECE MOUNTED TO DRAW-ALIGNER ARM
FOR THE APPLICATION OF LOADS AT ROOF HEIGHT
DRAW ALIGNER, LATER VERSION
SA.Ml
810-4
_J
Page 704
Equipment, later design
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LOADS MAY BE APPLIED IN AN UPWARD DIRECTION BY
MEANS OF AN ADDITIONAL HYDRAULIC CYLINDER AND
AN EXTENSION PIECE
SIDE SUPPORT
ALIGNMENT
SIDE MOUNTING FOR USE WITH A 4-TON HYDRAULIC
CYLINDER
SIDE MOUNTING USED FOR APPLICATION OF DOWNWARD LOAD
810-5
JIG WITH EQUIPMENT
1. Alignment jig, later design
2. Wheels
3. Side support
4. Draw aligner
5. Extension
6. Support set, Saab 99 (also for alignment jig of earlier design)
7. Support set, Saab 95 L, 96 L (also for alignment jig of earlier
design
WEI
Page 705
Mounting the car in the jig
The simplest method of mounting the car in the jig is to
use a side car lifting ramp with one or two pillars.
windshield post. A ruler is first placed as shown in Fig. 2
to check the vertical position, and then is shown in Fig. 3
to check the horizontal position.
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FRONT FENDER FIXTURE, FIG. 1
0
MOUNTING THE CAR IN THE JIG
The car can also be mounted in the jig by hoisting it onto
high trestles by means of a high-lift jack, and then rolling
the jig in under the car. A side lifting ramp should then
be used to lift the car onto the jig mountings.
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LIFT WITH TRESTLES AND JACK
S 4091
Front fender fixture
Front fender fixture 8290637 is intended for checking
and location of the front fender in connection with collision damage repairs.
Figure 1 illustrates how it is used.
The fixture also has location studs for the purpose of
checking the position of the top hinge attachment in the
FRONT FENDER FIXTURE, FIG. 2 AND 3
1. Hinge screw
2. Plate nut for hinge screw
3. Locating stud
4. Ruler
5. Front fender fixture 8290637
810-6
Page 706
CHECKING BODY DIMENSIONS
If any part of the body has had to be renewed or straightened,
it is important to check the measurements of the door open-
ings and the attachment points of the suspension and power
unit. Diagonal measurements should also be made to check
that there is no residual skew or asymmetry after repairs.
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810-7
9'AB
Page 707
Dimension data (see also drawings on next page)
Measurements
in.
mm
Ref.
Measurement points
I
0
Horizontal reference line
1
24.6
2
10.61 ± 0.04
3
74.1
4
Underside of scuff plate
625
± 3
Centerline - forward hole 1l, control arm
269.6
± 1
Forward hole 1) - rear hole 1)
±0.08
1883
± 2
Rear hole 11, front - forward hole 1), rear
55.9
± 0.16
1421
± 4
Front hole 1) - centerline
5
52.8
± 0.12
1340
± 3
Rear floor
6
44.00 ±0.12
1117 .5
± 3
Rear floor
7
1.3
± 0.06
33
± 1.5
Recess,rear floor
8
6.46 ± 0.08
164
± 2
Hole 1), spring linkage - hole centerline in the middle between the holes
9
41.7
± 0.12
1060
± 3
Hole 1), spring Iinkages
10
46.5
± 0.16
1180
± 4
Scuff plate, inside top edge
11
32.2
±0.08
817
± 2
Front floor
12
30.7
±0.08
779
± 2
Outer holes1), control arms
13
43.3
± 0.12
1100
± 3
Front floor
14
82.5
± 0.12
2096
± 3
Diagonal, rear outer hole 1l, control arm - forward hole, spring linkage
15
12.30 ±0.12
312.5
± 3
Horizontal reference line - front floor upper surface on centerline
16
9.34 ± 0.12
236.9
± 3
Dash panel - windshield member, top front on centerline
17
21.48 ±0.12
545.5
± 3
Surface of glassdown centerline
18
57.3 2 ) ± 0.24
1457 2 ) ± 6
Diagonal, door frame
19
47.1 2 ) ±0.74
1197 2 ) ± 6
Diagonal, door frame
21
16.40 ±0.12
416.5
± 3
Forward hole 11,spring linkage - side member on centerline
22
23.5
±0.12
596
± 3
Surface on glassdown centerline
23
20.1
± 0.12
511
± 3
Horizontal reference line - rear floor, upper surface on centerline
24
49.6
±0.12
1260
± 3
Holes1) for hood attachment
25
26.67 ± 0.12
677.5
± 3
Top forward attachment points of upper control arm
27
50.7
±0.12
1288
± 3
Rear floor, upper surface
28
52.6
±0.16
1336
± 4
Scuff plate, inside top edge
29
62.4
1585
± 3
Diagonal, bottom of roof side member - inside outer edge of scuff plate
30
46.6
±0.12
± 0.08
0.24
1170
+ 2
- 6
Side member, bottom edge
41
43.3
±0.08
136
± 2
Horizontal reference line - hole 1) side member
42
17.7
±0.12
448
± 3
Forward hole 1), spring linkage V - forward hole 1), side member
attachment
43
38.8
±0.12
986.6
± 3
Forward hole 1), spring linkage H - forward hole 1), side member
attachment
± 0.12
1) Center of hole.
2 ) Tolerance to give best door fit.
SAAB
810-8
Page 708
24
A-A
27
S3143
REFERENCE DATA FOR CHECKING BODY DIMENSIONS
ENGINE SUSPENSION
810-9
SAM!
Page 709
Engine suspension
Measurements
in.
mm
Ref.
Measurement points
31
1.2
±0.08
30
± 2
Centerline - hole 1), forward engine attachment point
32
20.3
±0.12
516
±3
Holes 1), rear engine attachment points
33
10.2
±0.08
258
± 2
Hole 1), rear engine attachment point - centerline
34
27.1
±0.12
687
±3
Hole 1), forward engine attachment point - centerline between holes,
rear engine attachment points
35
5.6
±0.12
143
±3
Horizontal reference line - engine member, upper surface at attachment
point
36
6.6
±0.12
167
±3
Horizontal reference line - floor member, upper surface at attachment
point
1) Center of hole
Sealing line
View 1
Fender end
Outer valance
View4
View3
VARIANT
DIMENSIONS, 4-DOOR
MODEL
S 3145
Variant dimensions, 4-door model
Ref.
Measurements
in.
mm
37
51.5 2 )
1307 2 )
View 1 - View 4
38
38.2 2 )
970 2 )
View 1 - Forward hole 1l, hinge
39
43.3 2 )
1099 21
View 2 - Forward hole 1), hinge
40
45.6 21
1157 2 )
View 1 - View 3
Measurement points
1) Center of hole
2 ) Tolerance to give best door fit
SA_MI
810-10
Page 710
Deviations from the nominal body dimensions of the Saab 99 Combi Coupe
Measurements
Ref.
Measurement points
in.
mm
44
19.8
504
Horizontal reference line - rear floor, upper surface on centre line
45
45.8
1164
Mounting of the pneumatic springs
46
48.8
1240
Width of door opening at the height of the rear floor, upper surface on
centre line
47
64.1
1628
Diagonal, pneumatic spring mounting - rear edge of door opening at
height of the rear floor, upper surface on centre line
48
23.62
600
Centre of hinge pin 1l
49
11.81
300
Reference line - top of rear sill plate
50
51
33.1
59.0
840
1499
Pneumatic spring mounting - plate edge in the door gutter
Front hole - rear edge of bolt line
1l Centre of hole
Centre of
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S 4805
VARIANT
810-11
DIMENSIONS, SAAB 99 COMB! COUPE
SAAB