Page 21
644-4 Power-assisted steering system
7 Disconnect the return pipe from the control
valve (16-mm spanner), Tie the return pipe
to the speedometer cable.
8 Plug the openings in the control valve.
9 Remove the pinch-balt from the universal
joint between the pinion shaft and the inter-
mediate shaft.
10 Remove the securing bolts for the rack-and-
pinion gear assembly.
Saab 900
Page 22
Power-assisted steering system 644-5
11 Separate the pinion shaft from the inter-
mediate shaft.
i2 Turn the rack-and-pinion gear assembly to-
wards the front, so that the pinion shaft
points downwards, and then move the as-
sembly as far as it will go to the right (looking
towards the front of the car).
13 Rotate the pinion shaft until the rack is atthe
RH end of its travel.
14 Position the LH track rod underneath the
subframe member.
15 Move the rack to the LH end of its travel and
lower the assembly out of the car.
Saab 900
Page 23
644-6 Power-assisted steering system
To refit
4 Move the rack to the LH end of its travel (pin-
ion end), held the assembly with the pinion
shaft pointing downwards and lift the as-
sembly into position.
2 Move the rack to the RH end of its travel.
3 Lift the LH track rod over the subframe
member,
4 Return the rack to the centre position. The
slot for the pinch-bolt In the pinion shaft
should be towards the rear of the car when
the pinion shaft is pointing downwards.
5 Rotate the entire assembly forwards to bring
the pinion shaft to the top.
6 Connect the pinion shaft to the intermediate
shaft and refit the pinch-bolt and nut, leav-
ing them slack.
Page 24
Power-assisted steering system 644-7
? Tighten the fixing bolts.
8 Tighten the pinch-bolt in the universal joint
between the pinion shaft and intermediate
shaft.
9 Check the condition of the "0" ring on the re-
turn pipe and then reconnect the return pipe
to the pinion housing (16-mm spanner).
Saab $00
Page 25
644-8 Power-assisted steering system
10
a2:
12
13
14
15
16
17
Check the condition of the "O” ring on the
flow line and reconnect the flow pipe to the
pinion housing (18-mm spanner).
Fit a strap around the return pipe and rack
housing and use a cable tie to hold the pipe
to one of the flow pipes between the control
valve and servo cylinder.
Note that the pressure-equalizing capillary
tube between the rubber gaiters must not be
clipped or tied In any way.
Cars with B201 engine, M87 and earlier: Fit
a cable tie around the handbrake cables and
rack housing.
Screw the track rods onto the track-rod ends
until they make contact with the locknuts.
Leave the locknuts slack until after the toe-
in has been checked.
Refit the wheels.
Fill the system with 75cl (O.8liqqt) of
Texaco 4634 power steering fluid.
Bleed the system as follows: with the engine
switched off and the front wheels off the
ground, turn the steering whee! from lock to
lock three or four times.
Lower the car, start the engine and turn the
steering wheel lock to lock twice more to
check that the system is working properly.
Check the fluid level.
Measure the toe-in and adjust as necessary,
18 Tighten the locknuts on the track rods.
Snah 900
Page 26
Power-assisted steering system 644-9
To dismantle
1 Measure and note the distance between the
locknut and the end of the track rod (on both
sides) to minimize adjustment of toe-in on
refitting, and then remove the nut.
]
”
2
Wa oe) 2 Remove the rubber gaiters and pressure-
equalizing capillary tube.
@
8
wn
3 Remove the inner ball joint at the greater
distance from the pinion as follows:
© Undo and slide back the end stop.
@:
©
FGaes.
S6A8S
© Clamp the rack in a soft-jawvice and undo
the inner ball joint using tool 89 96 480.
N.B.
Under no circumstances hold the pinion when
undoing or tightening the ball joint.
Saab 900
Page 27
644-10 Power-assisted steering system
4 Remove the circlip from inside the end of the
rack housing as follows:
® Move the rack to the end of its travel at
the opposite end of the rack housing to
the pinion. Clamp the rack in a soft-jaw
| vice and slide sleeve 89 96 407 over the
rack.
e Push in the spring-loaded seal retainer by
| screwing on the inner ball joint.
e Remove the rubber cap from the narrow-
bore hole in the end of the rack housing
and push in the end of the circlip by
means of a sawn-off electrical screw-
driver (8x15 mm). Bend back and with-
draw the circlip using a hook made froma
piece of 1-mm piano wire (see drawing).
ee
5 Remove the ball joint and sleeve.
6 Clamp the rack housing in a soft-jaw vice
and unscrew the inner bal! joint from the pin-
ion end of the rack housing using tool
89 96 480.
Saab 900
Page 28
ii nt. cca)
Power-assisted steering system 644-11
7 Remove the locknut for the damper yoke.
au
8 Remove the adjusting screw and spring.
9 Lift out the damper yoke. If it proves obsti-
nate, tap the housing gently on the work-
bench.
10 Tap off the end cap on the bottom of the pin-
ion housing.
Saab 900
Page 29
ne
644-12 Power-assisted steering system
11 Undo the locknut. Use a pair of water pump
pliers to hold the pinion shaft, taking care
not to damage the splines.
12 Removethe circlip from the top of the valve.
13 Press out the pinion and valve complete with
needle bearing, bearing race, hydraulic seal
and dust cap. Start by using tool 8391 849
(special tool for section 2 - engine) followed
by an M8 bolt, if necessary. Use ring
87 90 644 (special tool for section 4 - gear-
box) as a support.
$643
Saab 900
Page 30
Power-assisted steering system 644-13
14 Withdraw tne rack.
@) 15 Remove the outer hydraulic seal (1), the
wave spring washer (2) and the bush (3).
16 Remove the inner seal using tool 89 96 399
and a long drift.
| Saab 900