Page 361
Nov. 1971
CONTENTS
411
412
Clutch
Clutch control
Manual transmission
430
431
432
471
473
475
General
Removal and installation
Transmission control
Disassembly, assembly
Differential and pinion/crown wheel gear
Universal joints
Automatic transmission
440
442
444
472
473
475
General, road test and fault diagnosis
Removal and installation
Transmission control
Disassembly, assembly, adjustment
Differential and pinion/crown wheel gear
Universal joints
Page 362
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Page 363
CLUTCH
General
The car is fitted with a single dry plate clutch of dia-
phragm spring type. The principal clutch components are
the disc, pressure plate assembly and release bearing. The
clutch disc consists of a resilient steel plate attached to a
hub which slides on splines on the clutch shaft. The clutch
linings are riveted to both sides of the disc.
The pressure plate assembiy consists chiefly of the pres-
sure plate, pressure spring (diaphragm spring) and hous-
ing. The spring acts as a lever and as pressure spring. The
pressure plate assembly is an integral unit and must not
be disassembled.
The release bearing is a ball bearing of special construc-
tion with an elongated outer ring that presses direct
against the diaphragm spring when the clutch is let out.
!t is mounted on a guide sleeve screwed to the transmis-
sion case. As from transmission No. 45459 a new release
bearing has been introduced. The new beari ng has an O-
ring bearing on the guide sleeve. The operation of the
clutch is hydraulic; the clutch pedal actuates a master
cylinder connected by a hose to a slave cylinder, which
is mounted on the transmission case. The action of the
slave cylinder is transmitted to the release bearing by a
clutch lever journaled in the transmission case.
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PRESSURE PLATE ASSEMBLY, SECTIONAL VIEW
1. Pressure plate
2. Housing
3. Diaphragm spring
4. Pressure bearing rings
5. Release bearing
411-1
Jan. 1973 SAAB
Page 364
Removing
Remove the engine hood (see section 201).
2. Disconnect the battery ground cable.
3. Drain off coolant by opening the radiator drain
cock,
4. Disconnect the electric wiring from the radiator
fan motor and from the fan switch on the radiator.
5. Disconnect all hoses from the radiator. As from
model 1972: Remove also the air cleaner cold air
hose.
6. Remove the front sheet complete with radiator (see
section 201).
7. The rest of the job can be done more easily if the
wiring to the ignition coil, temperature transmitter
and oil pressure switch is first disconnected.
8. Undo the clutch cover retaining screws and remove
the cover.
9. Remove the spring at the slave cylinder.
10. Slacken the clutch adjustment by backing off the
adjusting screw; lower the clutch lever.
11, Free the lock ring and remove the sealing cap over
the clutch shaft.
12. Undo the clutch shaft center screw with washer and
O-ring.
13. Remove the clutch shaft using tapping-out ham-
mer 839027 and joint 839001 (5/16’" UNC) alt.
879052 (M8) depending on shaft design.
14. Back off and remove all clutch retaining screws
except the two at the top; these are left in place
to prevent the clutch from falling down.
15. Undo the three retaining screws of the release bear-
ing guide sleeve.
16. Fit clutch tool 839207 and clamp the clutch
and release bearing together. The pressure plate
assembly, clutch disc and release bearing with guide
sleeve can then be taken out.
ey
PULLING THE CLUTCH SHAFT
Tools 839001 and 839027
411-2
REMOVING THE CLUTCH
Tool 839207
Assembling
di.
Place the clutch disc in the flywheel. Press together
clutch and release bearing with tool 839207. If
necessary use guide spindle 879041 for centering
of release bearing, see fig. Place the guide sleeve in
the release bearing and place the clutch assembly
in position, 4
CENTERING OF RELEASE BEARING
Too! 879041
2
True up the center of the clutch disc using the
clutch shaft. Then check that the clutch slips on
to the locating pins and tighten the top screws
lightly.
Tighten the three retaining screws of the guide A
sleeve. é
CAUTION
The gasket is not symmetric.
Remove the clutch tool and tighten the clutch re-
taining screws.
Insert and tighten the clutch shaft center screw
with washer and O-ring.
Fit the sealing cover and lock ring over the clutch
shaft.
Line up the clutch lever and fit the spring at the
slave cylinder.
Dec, 1975
Page 365
8. Tighten the adjusting screw so that the clutch is Clutch disc
released when the clutch pedal is depressed.
Adjust the clearance between the diaphragm spring Inspecting the clutch and exchanging clutch linings
and the release bearing by turning the adjusting
screw and tighten the lock nut. The clearance bet- 1. Inspect the surface of the flywheel where the clutch
ween the diaphragm spring and the release bearing disc makes contact. Blueing or small cracks on the
should be 0.06” (1.5 mm), corresponding to a mea- surface are of no particular importance, but if there
sured 0,12 + 0.02” (3 + 0.5 mm) at the outer end are any deep scratches the flywheel ought to be
of the clutch lever. machined down or exchanged.
2. Check the pressure plate in the pressure plate assem-
bly for scratches and distortion. If there are any irreg-
ularities the plate should be exchanged.
. Check the release bearing for noise, wear, etc.
. Check the disc for wear and fit new linings if necessary.
5. Before riveting on the new linings, check and if neces-
sary adjust the set of the disc.
Sw
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Inspecting the pressure plate assembly
~ Check the pressure plate for cracks and scratches. Check
4 1 that the surface of the plate is not cambered, using a rule
2 and feeler gauge as illustrated. A gap of not more than
340.5mm
MEASURING CLUTCH CLEARANCE
1. Adjusting screw 3. Clutch lever
2. Lock nut 4. Slave cylinder
. 9. Mount the clutch cover.
y) 10. Mount the front sheet complete with radiator. Con-
nect the coolant hoses.
11. Connect electric wiring. CHECKING THE PRESSURE PLATE
12. Fill the radiator with coolant.
r Ages Bin ste aie 3209 0.0012" (0.03 mm) is allowable at the inner edge of the
ight alignment. the :
\ o, 14, Check the headlight alig friction surface, but there must be no gap at all between
Changing clutch linings the rule and the outer edge of the friction surface. Make
this check at several points. Check that the pressure spring
1. Drill out the old rivets and remove the old linings. is not cracked or otherwise damaged.
2. Check that the set of the tongues is regular and that Check that the release bearing turns freely when rotated
the disc is not out of true. Check also that the rivets under slight axial pressure.
in the hub are secure and that there are no cracks. The
disc must slide freely on the clutch shaft without ary
radial play.
3. Rivet on the new linings. The thickness of the disc is
to be checked under a compressive force of 4230 N
(948 Ib., 430 kg), the correct thickness being 0.270—
0.290 ”' (6.85—7.37 mm).
CORRECT POSITION OF CLUTCH LINING RIVETS
Nov. 1971 SAAB 411-3
Page 366
CLUTCH CONTROL
Removing and installing the clutch pedal
1. Remove the split pin and washer and pull out the shaft
bolt for the master cylinder push rod.
2. Unhook the clutch pedal return spring.
3. Remove the split pin and washer from the pedal shaft.
Take out the pedal.
4. Remove the spring if necessary.
5. Lubricate the pedal bearing with chassis grease before
reassembling.
Reassemble in the reverse order.
Adjusting clutch play
The clutch play, i.e. the clearance between the release
bearing and the diaphragm spring, is regulated by an
adjusting screw that threads into the transmission case
and acts as the fulcrum of the clutch lever. The gap is
increased when the screw is backed off. The gap should
be checked at the outer end of the clutch lever (see illus-
tration on p. 411—2), where it should be 0.12 + 0.02”
(3+ 0.5 mm).
ADJUSTING CLUTCH PLAY
Removing the release bearing and clutch lever
To remove the release bearing or clutch lever, proceed in
the same manner as when removing the clutch.
412-1 SAAB
Master Cylinder
General
The master cylinder consists of a cast housing surrounded
by a sheet metal fluid container. The operating elements
consist of a push rod, piston, piston seal and return spring
(see illustration). The end of the push rod is sealed by a
rubber bellows.
CLUTCH MASTER CYLINDER
1. Housing 7. Seal
2. Spring 8. Lock ring
3. Spring retainer 9, Sealing bellows
4. Seal 10. Push rod
5. Washer 11, Shaft bolt
6. Piston
Removing
1. Disconnect the hose from the slave cylinder and Pump
out the fluid into a clean container.
2. Disconnect the push rod from the clutch pedal by re-
moving the split pin and shaft bolt.
3. Undo the retaining screws and remove the master cyl-
inder.
Nov. 1971
Page 367
Installing
1. Mount the master cylinder.
2. Connect the push rod to the clutch pedal by inserting
the shaft bolt through the holes in the fork of the push
rod and the hole in the clutch pedal. Locate the push
rod and secure with the split pin.
3. Connect the hose.
4. Bleed the system.
Disassembling
Pull back the sealing bellows and remove the lock ring
with a pair of pliers. Take out the push rod with the
washer. The piston and its seal is now visible. Remove
the piston, washer, piston seal and spring. Take the seal
carefully off the piston. Examine the cylinder walls; if
they are smooth and unscratched, new seals can be fitted,
but if the surface of the cylinder bore is rough, a complete
new cylinder should be installed. If the old seals on the
piston are enlarged or swollen, they are probably contam-
inated with mineral oil; this is the most common cause
of cylinder malfunction. Seals made of natural rubber
are very sensitive to mineral oil, and even small quantities
of oil can cause them to swell with time. If this is suspected
change all the seals and flush the system with clean hydrau-
lic brake fluid.
Assembling
Fit the return spring with its retainer. Lubricate the pis-
ton and seals thoroughly with Girling Rubber Grease 3
and fit the packing, washer and piston with seals.
NOTE
The washer must be fitted with the convex side
facing the piston (see illustration).
—=-
CORRECT POSITION OF WASHER
Fit the push rod into the cylinder, followed by the washer
and lock ring, which are located in the cylinder housing
groove. Replace the sealing bellows or fit a new bellows
if the old one is damaged.
Dec. 1975
Slave cylinder
General
The slave cylinder consists of a cast-iron housing with an
operating unit consisting of a push rod, lock ring and pis-
ton. A rubber cap seals the end of the push rod. The cyl-
inder housing is provided with a bleeding nipple.
Bleeding the master and slave cylinders
Nn
. Connect a hose (about 1/4’ or 6 mm ID) to the slave
. Fill the master cylinder header tank with brake fluid.
. Open the bleeder nipple on the slave cylinder a half
SLAVE CYLINDER
1. Push rod 4. Piston
2. Sealingcap 5. Piston seal
3. Lock ring 6. Housing
cylinder bleeder nipple, and place the free end ina
collecting vessel part-filled with hydraulic brake fluid.
turn.
. Place the coolant system tester over the filler opening
of the master cylinder (see illustration).
BLEEDING THE CLUTCH SYSTEM
. Pump one or more times until all air has been expelled
from the system.
. Close the slave cylinder bleeder nipple.
. Check that all air has been expelled by pushing down
the clutch pedal.
412-2
Page 368
GENERAL
Manual transmission, up to and incl. chassis No. 99722003498
The transmission is designed for front-wheel drive and is O° : ;
so constructed that all shafts with gears, free wheel, dif- ~ | ‘ ~ _/h.
ferential and inner universal joints form an integral = IO
unit. ; 7 + —.
The transmission incorporates a four-speed gearbox. All —
forward gears are synchronized, while reverse is engaged .
by a sliding gear. The shafts are journaled in the transmis-
sion case with ball and tapered roller bearings. The pinion
shaft gear is journaled direct on the shaft without bush- Sua
ings. All gears except reverse are in constant engagement TRANSMISSION UP TO AND INCL. CHASSIS NO. 99722003498
and have spiral-cut teeth.
The front of the transmission assembly consists of a pri-
mary gear, which transmits shaft power from the clutch
to the actual gearbox. The latter is located underneath
the engine and part of the transmission case serves as
an engine oil sump.
TRANSMISSION UP TO AND INCL. CHASSIS NO. 99722003498,
EXPLODED VIEW
430-1 SAAB Nov. 1971
Page 369
The operation of the transmission is illustrated in the Reverse drive is provided by an extra shaft, the reverse
diagram below. Shaft power is transmitted through the gear shaft. A gear journaled on this shaft is in constant en-
clutch, primary gear and free wheel to the input gear in gagement with first gear on the intermediate gear. The re-
the gearbox. When the car is being driven in first gear, verse gear shaft also carries a sliding gear wheel connected
power is transmitted by the intermediate gear to the pin- to the reverse gear by splines. The sliding wheel can be
ion shaft, the No. 1 gear, which is journaled on the pinion moved into engagement with a gear on the pinion shaft;
shaft, being locked to it by a sliding muff. this last-named gear forms part of the coupling muff for
For driving in second or third, power is transmitted to first and second gear synchronization. Thus when the car
the pinion shaft in the same way but with No. 2 or No. is being driven in reverse, power is transmitted from the
3 gear locked to the pinion shaft by a coupling muff. intermediate gear to the reverse gear and sliding wheel,
For driving in top gear, the input shaft in the gearbox which in turn drives the pinion shaft through the gear
is locked to the pinion shaft direct by a coupling muff, on the coupling muff. This arrangement reverses the
i.e. in this case power is not transmitted through the sense of rotation of the pinion shaft.
intermediate gear.
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TRANSMISSION UP TO AND INCL. CHASSIS NO. 9972003498,
SCHEMATIC DIAGRAM
1. Clutch shaft
2. Primary gear
3. Free wheel
4. Intermediate gear
5. Reverse gear shaft
6. Pinion shaft
7. Differential housing
B=Reverse gear
Jan. 1973 SAAB 430-2
Page 370
Manual transmission as from chassis No. 99722003499
The operation of the transmission is illustrated in the
diagram. Shaft power is transmitted through the clutch
and primary gear to the input gear in the gearbox. When
the car is being driven in 1st gear, power is transmitted
by the intermediate gear to the pinion shaft through the
No. 1 gear, which is journaled on the pinion shaft and
locked to it by a sliding muff.
For driving in 2nd or 3rd, power is transmitted to the
pinion in the same way but with No. 2 or No. 3 locked
to the pinion shaft by a coupling muff. For driving in
top gear, the input shaft in the gearbox is locked to the
pinion shaft direct by a coupling muff, i.e. in this case
power is not transmitted through the intermediate gear.
Reverse drive is provided by an extra reverse gear shaft.
A gear journaled on this shaft is in constant engagement
with 1st gear on the intermediate gear. The gear pinion
can be engaged with a gear on the pinion shaft. This gear
is placed behind the 1st gear on the pinion shaft. Thus
when the car is being driven in reverse, power is trans-
mitted from the intermediate gear to the reverse gear,
and thence to the pinion shaft. This arrangement reverses
the sense of rotation of the pinion shaft.
TRANSMISSION AS FROM CHASSIS NO.
99722003499
TRANSMISSION AS FROM CHASSIS NO. 99722003499, EXPLODED VIEW
430-3
Aug. 1973