Page 11
Alignment against panel or wall
4 Check the tyre pressures, load the car as it
would normally be loaded and position the
car ona level surface, 16.5 ft (5m) from the
panel.
2 Mark on the panel the height of the head-
lamp centre above the ground.
3 Switch on the dipped beams and cover one
lamp.
4 Check and adjust the beam so that the hori-
zontal part of the light/dark boundary lies
. 2.0 in (50 mm) below and to the left (right for Aligning the lamp against a panel - right asym-
\ a left asymmetric lamp) of the headlamp metric lamp
‘ centre. See the illustration. The sloping part
of the light/dark boundary should lie fully to H = Height of headlamp centre above the ground
the right (left for a left asymmetric lamp) of
the mark, and should thus meet the horizon-
tal part precisely under the headlamp
centre.
5 Align the other headlamp in the same way.
6 Check that the full beam has an even
spread. If the light pattern is irregular, of if
any difficulty is experienced in setting the
dipped beam correctly, check that the bulb
is properly seated, or fit a new bulb if neces-
Sary.
Page 12
Reversing light switch (manual
gearbox)
On cars with manual gearbox, the reversing light
switch is located under the console, to the left of
the gear lever. The switch closes when the gear
lever is moved to the reverse gear position.
In certain cases, the reversing light switch may
enter the gear-lever housing too far when it is
screwed in, and be damaged. This can be
avoided by fitting a washer (part No. 79 74 686)
between the switch and the gear-lever housing.
Page 13
361-2 Direction indicators
To remove the direction indicator stalk
switch
The direction indicator/dip switch and wiper/
washer switch are located on a bracket fitted on
the steering column bearing bracket. The brac-
ket can be removed after removing the steering
column bearing bracket.
Page 14
Steering swivel member 631-1
Steering swivel member
Checking ball-jointplay ....... 634-4
Replacingaballjoint ........ 631-2
Replacing ball-jointseals ...... 631-3
Checking ball-joint play
For any ball-joint play to be detected, the wish-
bones must be relieved of the tension imposed
by the coll spring and damper.
1 Fitinsert83 93 209 under the top wishbone.
2 Check the axial play in the top and bottom
ball joints:
Use a pair of water pump pliers to compress
the ball joint.
Maximum axial play: 2mm.
3 Check the radial play in the top and bottom
ball joints:
Insert a lever between the wishbone and the
steering swivel member. Take care not to
pinch and damage the rubber seal!
Maximum radial play: 1mm.
4 |nspect the rubber seals for damage and re-
place any that are defective
Saab 900
Page 15
631-2 Steering swivel member
Replacing ball joints
The following method applies to both top and
bottom ball joints,
1 Raise and support the car and remove the
road wheel.
2 Place a jack under the outer end of the
wishbone and raise the wishbone slightly to
relieve the load on the bump stop, Undo the
bottom mounting on the damper,
3 Lower the jack until the drive shaft is just
making contact with the edge of the aperture
in the body (leave the jack in position as a
support for when you remove the ball joint).
4 Undo the nut securing the ball joint to the
steering swivel member. Separate the ball
joint using tool 89 95 409.
5 Remove the ball joint from the steering
swivel member. Tie up or support the steer-
ing swivel member to prevent the brake lines
from being damaged.
6 Fit the new ball joint to the steering swivel
member and tighten the nut.
7 Using new locknuts, secure the ball joint to
the wishbone.
Saab 900
Page 16
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13 Adjustable inner bail joint (M81 and earlier)
14 Locknut
17 Track rod onwards)
18 Outer bearing cap
19 Nonadjustable inner ball joint (M82
20 Spacer
21 Gaiter
22 Clips
23 Locknut
24 Track-rod ends
THD
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g yoke
Dampin
Spring
T
Page 17
642-4 Manual steering system
Caution
The collapsible steering column must be
handled with care. If it is knocked or
treated roughly the preset length of the
telescopic section can be altered and the
energy-absorbing properties of the column
impaired.
When fitting the steering column, make
doubly certain that the splined joint is slid
fully home on the pinion shaft, so that the
groove in the shaft lines up with the pinch-
bolt. The joint should slide easily onto the
shaft; should the splines bind, never tap or
hammer the top of the column.
Similarly, never hammer or use any form of
impact tool to remove or refit the steering
wheel.
When the front wheels are off the ground,
never forcibly swivel a front wheel, causing
the steering to spin to full lock. This can
very easily result in serious damage to the
steering system. Operating the rack-and-
pinion gear by swivelling a road wheel will
cause the steering wheel to spin at high
torque, exerting a powerful torsional
stress on the steering column when the ro-
tation is arrested by the stop in the rack-
and-pinion gear.
To dismantie
1 Undo the iocknuts and unscrew the track-rod
ends.
2 Slacken the clips and remove the rack gait-
ers.
3 Separating adjustable inner ball joints:
© Drill out the pins in the inner ball joint
Drill diameter: 4mm; length of pin:
9.4mm.
Caution
Do not drill too deep.
Saab 900
Page 18
Manual steering system 642-5
@ Remove the outer bearing caps and
locknuts using’C’ spanner 83 90 197 and
water pump pliers.
4 Separating nonadjustable inner ball joints:
e Place suitable protection around the rack
and then drill out the tab in the locking
groove. Drill diameter: 4mm.
® Clamp the rack, pinion end down, in a
soft-jaw vice.
Caution
Under no circumstances must force be
applied to the pinion when undoing or
tightening the ball joint.
® Undo the inner ball joint using ’C’ spanner
89 96 472.
Saab 900
Page 19
644-2 Power-assisted steering system
To remove
1 Drain the fluid from the system as follows;
* Cars with B202 engine: Undo the fixings
for the fluid reservoir and disconnect the
return hose. Plug the opening in the re-
servolr.
Cars with B201 engine: Disconnect the
return hose from the pump and plug the
opening,
* Connect a length of hose or tubing to the
return hose and place the other end ina
receptacle having a capacity of at least
one litre.
@ Start the engine and allow the fluid to be
pumped out of the system. Turn the steer-
ing wheel twice from lock to lock to drain
the system completely.
¢ Cars with B202 engine: Reconnect the re-
turn hose to the fluid reservoir and secure
the reservoir.
Cars with B201 engine: Reconnect the re-
turn hose to the pump.
Page 20
Power-assisted steering system 644-3
2 Remove the front wheels.
3 Slacken the locknuts on the track rods but
then return them loosely to their original
position to minimize toe-in adjustment after
the steering gear has been refitted,
4 Unserew the track rod from the track-rod
end, ensuring that the rubber gaiter does not
turn with the rod. Measure the distance be-
tween the locknut and the end of the track
rod; this measurement will assist in setting
the correct toe-in after refitting the steering
Bear.
Remove the strap hoidi ng the return pipe to
the rack housing and Snip through the tie
securing the flow hose to the pipe between
the control valve and the servo cylinder,
Cars with B201 engine, M87 and earlier:
Snip off the tie round the handbrake cables
and rack housing.
Disconnect the flow pipe from the control
valve (18-mm spanner). Fit some absorbent
Paper to the end of the pipe to prevent spil-
lage and rest the hose on the exhaust pipe,
Saab 900