Page 411
ee ee ee
REMOVAL AND INSTALLATION 8:
Automatic transmission
Removal ts
For major work on the engine and transmission, the en-
tire power plant should be lifted out. Removal of the en- 8.
gine by itself is not recommended.
1. Remove the hood as follows:
Back off both the hood fastening screws. Lift off
the hood. For this you need a helper to hold one
side of the hood and help to lift it clear,
2. Detach the battery cables, Unclamp and lift out
the battery,
3. Drain off coolant through the radiator and engine
block drain cocks; open the bleeder cock on the
heater core. (Up to and incl. model 1973.)
4. Carbureted engine:
Detach the vacuum hose of the power assist cylin- 9.
der from the inlet manifold and pull the fuel hose
off the suction side of the fuel pump. 10.
4. Injection engine:
a, Detach the vacuum hoses of the power assist 11.
cylinder and the pressure transmitter from the
inlet manifold. 12.
b. Detach the fuel hoses from the tubes at the in-
let and outlet of the injection valves. 13.
5. Carbureted engine:
Undo the cable connections to the ignition coil,
serial resistance, temperature transmitter, oil pres-
sure transmitter, radiator fan, thermostat contact,
contact on automatic transmission, headlights and 14.
headlight wiper motor. 15.
5. Injection engine: 16.
a. Undo the cable connections to the ignition coil,
serial resistance, temperature transmitter, oil 17.
pressure transmitter, radiator fan, thermostat
contact, headlights, contact on automatic trans-
mission, and headlight wiper motor.
b. Undo the cable connections to the fuel injection
system from the distributor, injection valves, air
cleaner or inlet manifold and throttle valve switch 18,
and thermostat housing and from the temperature
transmitter and thermostat contact at the inlet
manifold.
19.
CAUTION
Do not detach the connections by pulling the cables.
Grip the contact pieces.
Injection engine:
a. Remove air cleaner complete with hoses.
b. Undo the throttle control wire from the driver
on the throttle housing,
Undo the hose clamps at the connections to the
thermostat housing, radiator, inlet manifold and
water pump.
a. Remove the four fastening screws from the front
sheet,
b. Remove the self-tapping screws holding the head-
light trim frames.
c. Remove the four lower self-tapping screws secur-
ing the headlights to the edge of the bodywork.
As from model 1972: Remove the headlights
from front sheet and body.
d. Remove the hood lock operating cable from its
fastenings at the dash panel and wheel housing.
e. Remove the front sheet, lifting forward and up-
wards,
Remove the protective cover on the exhaust mani-
fold at the exhaust pipe.
Disconnect the exhaust pipe from the exhaust mani-
fold.
Detach the ground cable from the transmission. As
from model 1973: Remove the alternator.
Jack up the front end of the car and place blocks
under the body.
Remove the screw for the gear selector wire from
the transmission. Move the gear selector lever to
Position ‘1’ and pull out the sheath from the trans-
mission. Fit tool 879038 on the wire, turn the tool
a little and pull out the wire.
Detach the speedometer cable from the transmission.
Undo the engine brackets.
Engage the lifting yoke 839240 in the two engine
lifting lugs.
Undo the larger clips round the rubber bellows on
the inner universal joints. Undo the lower end piece
from the control arm on the right-hand side. Turn
the steering wheel to the left and withdraw the uni-
versal joint, Raise the power plant slightly and with-
draw the left universal joint.
Raise the power plant to a suitable height for access
to the cable connections to the starter and up to and
incl. model 1972 alternator, and disconnect the
cables.
Hoist out the power plant. Fit protective caps over
the inner drivers and rubber bellows.
Installing the power plant
6. Carbureted engine: The front end of the car should be on trestles when fitting
a. Remove the air cleaner and preheater complete
with hose and ignition cable,
NOTE! Save the spacer sleeves under the outer
preheater casing (up to and incl. model 1972).
b, Detach the throttle control linkage from the
throttle shaft and remove the return spring. As
1.
from the 1972 model, detach the throttle wire a
from driver and bracket.
c. Detach the choke control wire and sheath from
the carburetor,
Dec. 1975 SARE
the power unit.
a. Check that the inner universal joints are packed
with grease.
b. As from chassis No. 99,033.917: Check the front
engine cushion. Check that the washer is properly
tightened on the screw,
Hoist the power plant with the lifting yoke 839240
and lower it into the engine compartment.
442-1
Page 412
CAUTION
Take care when installing the power plant up to and
incl. model 1972, to avoid damaging the fuel line
hose joint at the dash panel, After installing, check
that there is at least 0.4’ (10 mm) clearance between
the alternator belt pulley and the hose.
~o
10.
11.
12.
13.
14.
15.
16.
17.
18.
18.
442-2
Lower the power plant to a convenient working
height and connect the cables to the starter and up
to and incl. model 1972, alternator.
Assemble the inner universal joints as follows:
Hang the clips on the inner drivers.
Lower the power plant to about 2” (50 mm) from
the engine cushions, Assemble the inner universal
joint on the right-hand side, lower the power plant
to 1° (20—30 mm) from the engine cushions and
move the power plant to the right. Lower the power
plant on to the cushions and at the same time assem-
ble the left-hand universal joint. Connect the end
piece to the lower control arm.
a. Align the engine brackets. At the same time
guide the throttle control shaft into its bearing
(up to and incl. model 1971).
b. Bolt the power plant to the engine cushions.
Remove the lifting yoke.
a. Prish the rubber bellows over the inner universal
joint drivers and fit the clamps.
b. Wipe any surplus grease off the rubber bellows
and check that the bellows are not deformed.
Connect the speedometer to the transmission.
Connect the gear selector wire to the transmission.
Bolt the exhaust pipe to the exhaust manifold.
Lower the front end of the car.
Connect the ground cable. As from model 1973:
Refit the alternator.
Mount the front sheet complete with radiator and
connect the hood lock operating cable to the attach-
ment at the dash panel.
Reconnect the cables to the radiator fan, thermo-
stat contact, headlights and headlight wiper motor
and clip the bundle of wiring to the front sheet.
Connect the coolant hoses to the radiator, thermo-
stat housing, water pump and inlet manifold.
Connect the brake vacuum hose and fuel hose and
connect cables to the temperature transmitter, igni-
tion coil, contact on automatic transmission and oil
pressure transmitter. In the case of injection engines,
connect the vacuum hose to the pressure transmitter
and the cables to the starting contact.
Connect the throttle control to the throttle control
shaft and connect the choke control to the carbu-
retor. As from model 1972: Refit the throttle con-
trol wire to driver and bracket.
Carbureted engine:
Mount the air cleaner and preheater casing complete
with hose. Connect the ventilation hose. Connect
the ignition cable to the distributor and coil.
Injection engine:
Mount the air cleaner complete with hoses. Connect
the cables for the electrical fuel injection system to
the distributor, injection valves, air cleaner up to and
inc}. model 1972, or inlet manifold, thermostat hous-
————
ing and throttle valve switch and to the temperature
transmitter and thermostat contact below the inlet
manifold. Make sure that the rubber caps on the con-
tact pieces are in place.
CAUTION
The contact pieces only fit in one way and must
thus not be forced into place.
19,
20.
21.
22.
23.
Install the battery and connect the cables.
Close the radiator and engine block drain cocks,
fill with coolant and oil. Bleed the heater core
(up to and incl. model 1973).
Start the engine, checking oil pressure and coolant
temperature, Check the operation of the transmis-
sion, Check the operation of the radiator fan by
grounding the thermostat contact cable to the
radiator.
a. Mount the hood and connect the windshield
washer and headlight washer hoses.
b. Check the fit of the hood. Close the hood, open
the doors, and check that the door jambs clear
the rear edge of the hood.
c. Check the headlight alignment.
d. Refit the headlight trim frames.
Take the car out for a test run. Check the coolant
level after driving.
Separating engine from automatic transmission
q.
2.
3.
10.
11.
Clean the outside of the power plant.
Drain the engine oil.
Undo the screw located inside the crankcase using
a 1/2” socket and extension shank. This screw can
be reached at an inward angle through the engine
oil drain plug opening. Use a tool with a 3/8” square
grip (this applies to the 1970 model only).
Remove the cover over the flywheel ring gear.
Remove the starter, alternator and V-belt (up to
and incl. model 1972).
Remove the right-hand engine bracket.
Disconnect the throttle wire from the throttle hous-
ing (carburetor).
Remove the crankcase ventilation device and all
screws in the mating flanges of engine and transmis-
sion.
Undo the four screws fastening the flywheel ring
gear to the torque converter. On 1.7 and 1.85 | en-
gines the screws can be reached through a recess in
the starter mount. On 2.0 | engine the screws are
accessible near the crankcase ventilation connec-
tion housing.
Lift the engine carefully off the transmission.
Fit the torque converter support (special too!
879025).
Reassemble in the reverse order.
CAUTION
If the engine and transmission fail to separate, do
not attempt to force them apart without first check-
ing that all the screws have been taken out. Do not
forget the screw inside the crankcase (1970 model
only) or the transmission ventilation attachment on
the right-hand side over the mating flanges.
Dec. 1975
—
Page 413
TRANSMISSION CONTROL
Automatic transmission
Checking the gear selector lever cable
1. Move the selector lever to N. Check the clearance
against the segment.
2. Move the selector lever to D. Check the clearance
against the segment. The clearance in N and the
clearance in D should be the same. See illustration.
3. Check that P, R, 2 and 1 are in correct position.
S 3199
\
\
ADJUSTING THE GEAR SELECTOR LEVER HOUSING
1. The clearance in N and in D are the same.
Adjusting the gear selector lever cable
od
SECTION THROUGH GEAR SELECTOR LEVER HOUSING
“-NO2zn07
Park
Reverse
Neutral
Drive 1, 2, 3rd
Drive 1, 2nd
Drive 1st
1, Adjusting the wire with nut
Dec, 1975
FINE SETTING OF THE GEAR SELECTOR LEVER CABLE,
LATER DESIGN
=
. Remove the gear selector lever cover.
2. Slack off the gear selector lever housing nuts with tool
839123.
3. Lift the gear selector lever housing and turn it so that
the adjustment nuts of the wire will be accessible.
4. Adjust by screw the nuts on the outer cover so that
this will be displaced inwards or outwards.
5. After adjusting, the gear selector lever housing will be
reassembled, and the clearance in N and D will be
checked once again.
ADJUSTING THE GEAR SELECTOR LEVER CABLE
In the connection between the gear selector lever cable
and the automatic transmission case a fine setting can be
done. Earlier design: The fine setting is done with shims,
see illustration. Max. three shims can be fitted. Later de-
sign: The fine setting is done with a special adjusting nut.
Cable of later design fits to all types of transmissions.
Page 414
FINE SETTING OF THE GEAR SELECTOR LEVER CABLE,
EARLIER DESIGN
Adjusting the downshift valve
1. Connect a revolution counter to the engine and a pres-
sure gauge 879003 to the transmission.
2. Immobilize the wheels by applying the brakes.
CONNECTING THE PRESSURE GAUGE
Tool 879003
3. Start the engine and check that the idling speed is
properly adjusted.
. Move the selector lever to D.
. Read off the pressure on the pressure gauge.
. Rev up from idling by 500 rev/min.
. Read off the pressure again. It should be up by 20—30
psi (1.4—2.1 bar,kp/cm2), If the pressure rise is too
little, the control cable must be adjusted outward, if
the pressure rise is too high, the control cable must
be adjusted inward.
NOD
NOTE
The pressure should be 50—70 psi (3.5—4.9 bar,
kp/cm2) in idling with gear selector lever in D.
444-2 SAAB
ADJUSTING THE THROTTLE CABLE ON CARS WITH IN-
JECTION ENGINES UP TO AND INCLUDING THE 1971
MODEL
ADJUSTING THE THROTTLE CABLE, INJECTION ENGINE,
AS FROM THE 1973 MODEL
ADJUSTING THE THROTTLE CABLE ON CARS WITH 1.85
LITER CARBURATED ENGINES UP TO AND INCLUDING
THE 1971 MODEL
Dec. 1975
Page 415
wv
ADJUSTING THE THROTTLE CABLE, CARBURETOR EN-
GINE, MODEL 1972
ADJUSTING THE THROTTLE CABLE, CARBURETOR EN-
GINE, AS FROM THE 1973 MODEL
Changing the gear selector cable
1. Remove the gear selector housing so that the cotter
pin securing the wire to the gear selector rod can be
driven out. Then disconnect the cable from the hous-
ing by undoing the two screws holding the wire clamp.
2. Disconnect the cable from the transmission casing using
the special too! 879038.
REMOVING THE GEAR SELECTOR LEVER CABLE
Tool 879038
3. Take off the heater duct and remove the old cable.
4. Fit a new cable, being sure to obtain a perfect seal
where it passes through the toeplate, and replace the
heater duct.
5. Connect the cable to the transmission and then pull
out the wire to engage position P in the transmission.
6. Connect the wire to the gear selector rod and the hous-
ing.
Then adjust the cable to roughly the correct position
with P engaged in the transmission.
7. Screw on the selector lever housing and check the
selector lever in the various positions, readjusting if
necessary (see directions for adjusting the gear selector
cable). ;
Note! As from transmission serial No. TB 1074 a new clips
on the gear selector lever cable has been introduced. The
new clips must be fitted as shown below.
§ 3202
GEAR SELECTOR LEVER CABLE WITH CLIPS
SAAB 444-3
Dec, 1975
Page 416
Changing the downshift valve cable
1. Disconnect the wire from the throttle damper at the
intake manifold and from its attachment to the re-
taining plate.
2. Drain oil from the automatic transmission and take
off the forward bottom cover.
3. Disconnect the throttle wire from the cam at the con-
trol valve on the valve housing and unscrew the cable
from the transmission casing.
REMOVING THE THROTTLE CABLE FROM VALVE
HOUSING
REMOVING THE THROTTLE CABLE FROM TRANSMISSION
CASE
4. Connect a new cable to the transmission casing and
hook it to the cam on the control valve, making sure
that the wire is properly positioned on the guide pulley.
5. Connect the wire to the throttle damper at the intake
manifold and adjust the wire roughly by noting the
position of the cam relative to the position of the
throttle damper. When the accelerator pedal is fully
depressed, i.e. in the kickdown position, the highest
point of the cam should be in contact with the kick-
down valve (see illustration).
6. Refit the bottom cover to the oil sump and fill the
transmission with oil. For adjustment of the throttle
wire, see the relevant directions.
THE CAM IN “KICK-DOWN” POSITION
1. Throttle wire 2.Cam 3. Valve
Identification table, throttle cables
The table below of dimensions and identification numbers
has been compiled to help you tell the cables apart.
An identification number is stamped into the hexagon nut
at the end of the cable which is connected to the trans-
mission.
444-4 SAAB Dec. 1975
Page 417
e B
; is
f +
el
Forked connection up to and incl. model 1971 S 4097
Identi- Lengths
Transmission type Year model Cable No. | fication]
No, & 2
mm in mm in
TB 1971 and earlier 870819 76 939.0 36.97 742.2 29.12
. TB 1972 870902 143 1009.1 39.73 769.9 30.31
y =) 269 1971 and earlier 870903 146 951.7 37.47 742.2 29.12
269 1972 870904 | 144 996.4 39.23 769.9 30.31
393 (carb.) 1973 and later 870910 | 210 1242.3 48.94 1029.9 40.55
399 (injection) 1973 and later 870909 | 211 627.1 24.64 430.0 16.93
\
Removing the gear selector lever housing Assembling the gear selector lever housing
1. Disconnect the battery earth cable. 1. Move the ignition switch to Drive.
2. Move the selector lever to P and take off the 2. Assemble the gear selector housing with the bottom
ignition key. cover and connect the wire bracket.
3. Loosen the lock nut under the button of the gear 3. Attach the house with one or two screws. Check and
selector lever and unscrew the button and nut. if necessary adjust the gear positions. See “Adjusting
4. Remove the scale cover. Before the cover can be the gear selector cable”. Assemble the house.
removed, the switch cable connections must be 4. Assemble the ignition switch cable. Move the gear
h : selector to P and take off the key.
5. Remove the scale light reflector and the lamp 5. Assemble the ignition switch light in the gear cover
socket for the scale light. and attach the cover.
6. Remove the heater control lever button. The right 6. Assemble the lamp socket and the scale light reflector.
one is acceable when the control lever is in its rear 7. Assemble the cable in the scale cover and attach the
y) position and the right seat is in its front position. cover,
‘ 7. Turn back the lever consol carpet and remove the 8. Assemble the gear selector lever buttons and heater
heater cover. control.
8. Remove the three gear cover retaining screws. Raise 9. Assemble the heater cover lid, carpet and battery
the cover and take off the ignition switch lamp. Re- cable.
’ ) move the cover.
9. Remove the ignition switch cable and note its posi-
tion.
10. Remove the retaining nuts for the gear selector le- F f 5
ver with tool 839123. Removing and installing the gear selector lever
11. Raise the gear selector lever housing and twist it. 1\\Remicive:the gear selector lever housing: Sea chi
Loosen the two bottom cover screws and take off a 9 ING: S88 this SoG:
the'wire bracket tension pin. 2. Turn the ignition key to Drive.
3. Take off the tension pin from the ratch sector.
4. Remove the screws and take off the lever,
Reassemble in reverse order.
Dec. 1975 SAA 444-5
Page 418
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Page 419
DISASSEMBLY, REASSEMBLY
Manual transmission up to and incl. chassis No. 99722003498
Disassembling and assembling of the gear box can be
done without separating the engine and the gear box.
IMPORTANT
Before disassembling the transmission, always mea-
sure up the positions of the pinion gear and crown
wheel. This is to check whether there is any error in
their locations. If the pinion and crown wheel assem-
bly is relatively new, i.e. if it has done less than 6,000
miles (10,000 km), it can be adjusted, but if the mile-
age is any greater the gears will have worn themselves
into a given position. In the latter case, they should
be reassembled in the same measured positions which
they occupied before disassembly.
S rea
TRANSMISSION MOUNTED IN WORK FRAME
Tool 839046
Proceed in the following order as far as necessary in order
to remove whichever component needs attention.
1. Clean off the transmission case and drain the oil.
2. Remove inner drive shaft joints with shafts. Up to and
incl. the 1969 model with the aid of puller 839147
and tapping hammer 839027. As from the 1970 model,
puller 879035 and tapping hammer 839027. Then re-
move the cover from the differential housing.
REMOVING THE INNER UNIVERSAL JOINTS
Tools 839027 and 879035
Dec. 1975 SAAB
. Remove the differential assembly by unscrewing the
differential bearing seats on both sides and removing
them with the help of puller 839147 and tapping ham-
mer 839027. Take out the differential assembly with
shims (if any). Safe the spacer washers and shims; the
latter must be replaced in their original positions on
reassembly unless the differential gear backlash has
been altered by the exchange of some component.
Before disassembling the differential, read section 473.
REMOVING THE DIFFERENTIAL BEARING SEATS
Tools 839027 and 839077
REMOVING THE DIFFERENTIAL ASSEMBLY
4. Remove the lock plate for the intermediate and reverse
gear shafts (see illustration). Using tool 839004, pull
the intermediate gear shaft until the intermediate gear
set drops free (see illustration).
471-1
Page 420
REMOVING THE LOCKING PLATE
SEPARATING THE PRIMARY GEAR HOUSING FROM THE
GEARBOX
6. Remove the intermediate gear set (see illustration).
er eetecee]
REMOVING THE INTERMEDIATE GEAR SET
PULLING THE INTERMEDIATE GEAR SHAFT
Tool 839004
7. Unscrew the transmission side cover, take out the
spring and ball catch for the gear selector rod, and
put them in a safe place (see illustration). Pull out
5. Separate the transmission at the joint between the the reverse gear shaft and lift out the reverse gear
gearbox and primary gear housing and lift away the with bearings and washers; then remove the gear
primary gear housing (see illustration). shift shafts and forks (see illustration).
471-2 SADE Jan. 1973