Page 421
Assembling the transmission
Having removed the component that needs attention,
clean all fragments of old gaskets and all traces of old
sealant compound off the covers. Inspect the trans-
mission case and all disassembled parts and wash them
in kerosene or similar. Then reassemble the transmission,
following the procedure described below.
1. Adjust the differential bearings to the correct com-
pression (see section 473 — this applies to manual
transmissions with serial numbers of 4007 and
higher).
2. Screw the two stud bolts (tool 839016) into the
transmission case. Then shim and locate the pinion
shaft assembly. Tap the assembly gently into posi-
tion, using a plastic mallet, drift 839011 and sleeve
839014. Then insert and tighten the four bearing
= housing screws and secure them with Loc-tite.
GEAR SHIFT SHAFTS AND FORKS
— r
©Ocd =
Saas
REVERSE GEAR WITH BEARINGS AND WASHERS
MOUNTING THE PINION SHAFT
Stud bolts 839016, drift 839011 and sleeve 839014
) 8. Undo the four pinion shaft retaining screws and tap
the pinion shaft gently out of the transmission case
with a drift (see illustration).
) If the position of the pinion shaft has been altered
by the fitting of new components, the gear setting
must be readjusted. See section 473.
NOTE |
|
|
3. Slide the coupling muffs on the pinion shaft to
their neutral positions and fit the gear shift forks
and gear assembly that the thrust washer is correctly
positioned. It will be easier to install the intermedi-
ate gear if this washer is first glued in place.
4. Locate the loose needles (25 in number) in the in-
termediate gear, using grease to hold them in place
until the intermediate gear shaft is inserted. Then
lay the intermediate gear set loose in the bottom
of the transmission case (see illustration).
TAPPING OUT THE PINION SHAFT
Deoa7s SAAS 471-3
EEE
Page 422
INSERTING THE INTERMEDIATE GEAR SET
5.
Coat the mating flange of the primary gear housing
with sealant compound, e.g. Tikatat 2, and screw
the primary gear housing to the transmission case.
This operation will be easier if polygrip pliers are
used to clamp the mating flanges together on both
sides alternately.
NOTE
Leave the screws slightly slack to avoid jamming the
loose intermediate gear set in the wrong position
before the intermediate shaft is insertea.
Alternative |:
Rock the transmission case gently until the inter-
mediate gear set comes into the right position, and
then insert the intermediate gear shaft using arbor
839026 and tool 839004, (see illustration).
INSERTING THE INTERMEDIATE SHAFT
Tool 839004
471-4
INSERTING THE INTERMEDIATE GEAR SHAFT
Tool 839019
“
Alternative II:
With installed engine.
Lift the intermediate gear with the hook wrench
839019 and insert the intermediate shaft as alt. |
(see illustration).
Tighten the primary gear housing screws.
Install the reverse gear and shaft, making sure to fit
the axial bearing at the same end as the spiral-cut
gear (see illustration). Fit the lock plate over the
reverse gear and intermediate gear shaft ends.
REVERSE GEAR WITH BEARINGS AND WASHERS
10.
Uy
12.
13.
Fit the reverse gear shift lever. Insert the spring and
ball catch for the gear selector rod. Coat the flange
of the transmission case side cover with sealant
compound, e.g. Tikatat 2, and then screw on the
cover.
Install the differential assembly (see section 473).
Inspect the shaft seals in the differential bearing
seats and fit new ones if necessary. Then mount
the seats and adjust the crown wheel backlash (see
section 473). Mount the two inner drive shafts
complete with inner universal joints, taking care not
to damage the shaft seals.
Coat the flange of the differential end cover with
sealant compound, e.g. Tikatat 2, and screw the
cover to the transmission case.
Fill the transmission case with oil (3 US qt, 5 Imp.
pints, 3 liters).
Dec. 1975
Page 423
Disassembling the pinion shaft
To disassemble the pinion, shaft, follow the instructions
already given for disassembling the transmission up to
the point where the pinion shaft is unscrewed. Then con-
tinue as follows:
PINION SHAFT WITHDRAWN
1. Release lock rings and remove spacers. Dismantle
bearings, gears and coupling muffs.
NOTE
The locking for the No. 2 gear is larger than others.
2. Put the pinion shaft in tool 839006 and loosen the nut
with aid of key 839007.
3. Set up the unit in a press. Press the pinion shaft from
the bearing housing using tools 839008 and 839009.
As alternative, fixture 879063 and holder ring 879065
can be used to press the unit apart.
$1815
TOOLS 839008 AND 839009
PRESSING THE SHAFT OUT OF THE BEARING HOUSING
Tools 839008 and 839009
$2443
PINION SHAFT WITH BEARING HOUSING AND INNER
BEARING RINGS
Dec. 1975 SAAB an-s
Page 424
4. Press the outer rings of the conical roller bearings out
of the bearing housing using tools 839009, 839010
and 839014.
S181
TOOLS 839009, 839010 AND 839014
Installing the pinion shaft
Having removed the part that needs attention, inspect all
disassembled parts and wash them in kerosene or similar.
Then reassemble and install, proceeding as follows:
NOTE
The bearings must be lubricated before being assem-
bled.
1. Press the outer rings of the conical roller bearings into
the bearing housing, using tools 839011, 839012 and
839014 (see illustration).
$2449
INSTALLING THE BEARING RACE INTO BEARING HOUSING
Tools 839011 and 839014
471-6 SALB
querer
2. Press on the roller bearing nearest the pinion gear until
it butts against its stop, using tool 839014 (see illustra-
tion).
PRESSING ON THE ROLLER BEARING NEAREST THE
PINION GEAR
Tool 839014
3. Mount a new spacer sleeve on the shaft.
4. Fit the bearing housing.
5. Fit the front roller bearing.
6. Set up the shaft in a press (see illustration). Using tool
839014, press the bearing housing slowly on and twist
it at the same time until resistance to twisting is felt.
$1820
PRESSING ON THE FRONT ROLLER BEARING
Tool 839014
Dec. 1975
Page 425
Set up the pinion shaft in a vice, using tool 839006.
Wind the dynamometer wire round the bearing
housing and pull the dynamometer handle. Tighten
the nut until the torque reaches the correct value as
indicated below. Lock with the securing plate.
Lightly oiled bearings:
New bearings 31.4—56.0 N (7—12.5 Ib., 3.2—5.7 kp)
dynamometer reading, which corresponds to a tor-
que of 1.8 + 0.5 Nm (7.3 + 0.5 Ib.in, 18 + 0.5 kpem).
Old bearings that have done more than 1.200 miles
(2.000 km): 10.0—34.0 N (2.2—7.7 Ib., 1.0—3.5 kp)
dynamometer reading, which corresponds to a tor-
que of 0.9 + 0.5 Nm (8 + 4.0 Ib.in, 9 + 5 kpem).
TIGHTENING THE PINION SHAFT BEARING
Tools 839006 and 839013
PINION SHAFT DISASSEMBLED
1. Spacers with rings 5. 3rd gear wheel
2. 1st gear wheel 6. 3rd—4th synchronization
3. 1st—2nd synchronization 7. Needle bearing
4. 2nd gear wheel
Fit the spacers and ring close to the nut.
Fit the 1st gear wheel with spacers and ring.
Fit the 1st—2nd synchronization with spacers and
ring.
NOTE
In gearboxes up to and incl. chassis No.
99722003498, the synchronizing ring for 1st gear is
of special design and can be distinguished from the
others by the fact that it lacks three teeth.
Dec. 1975
11, Fit the 2nd gear wheel with spacers and ring.
Note that the spacers and ring for the 2nd gear are
thicker.
12, Fit the 3rd gear wheel with spacers and ring.
13. Fit the 3rd—4th synchronization and lock ring.
14. Fit the needle bearing and the lock ring.
15. Fit the pinion shaft in the transmission case and
tighten it.
NOTE
Use tools 839011 and 839014 and stud bolt 839016
to mount the pinion shaft complete with bearing
housing in the transmission case.
16. Now measure and if necessary adjust the pinion
shaft (see section 473).
Removing the primary gear housing
To remove the primary gear housing, follow the instruc-
tions already given for disassembling the transmission.
According to these, the differential assembly must be
removed and the intermediate shaft gear freed before the
primary gear housing can be separated from the transmis-
sion case.
Disassembling
1. Separate the bearing housing from the primary gear
case (see illustration).
OPENING THE PRIMARY GEAR HOUSING
471-7
Page 426
NOTE
Remember to undo the clutch adjustment nut.
2. Remove the free wheel control (see illustration).
“
se
‘a PRIMARY GEAR TRAIN
1. Input gear
2. Center wheel \
3. Output gear
4
«
FREE WHEEL CONTROL z \
3. Pull the free wheel shaft. If it sticks, use drift
839018 to free it (see illustration).
Remove the free wheel hub from the free wheel
shaft using tool 879030.
If the needle bearing in the free wheel shaft needs
exchanging, it will have to be broken out, as it is
force fitted to the shaft.
Q@ 8
CENTER WHEEL OF PRIMARY GEAR ASSEMBLY WITH
SHAFT AND BEARINGS )
5. Remove the cap from the bearing housing, free the
lock ring from the shaft and press the output gear
out of the bearing, using tool 839009 as a sup- )
port and pressing with drift 839018 (see illustra- =
tion). Then press the bearing out of the bearing
housing using tool 839012 and sleeve 839014.
Pell $1024
FREEING THE FREE WHEEL SHAFT
Tool 839018
4. Remove the center wheel shaft from the bearing
housing and back off the center shaft nut using tool
839019 so that the center gear can be taken off.
Then press the inner ring off the center sHiaft using
tool 839014. If necessary, remove the friction wheel
from the center gear wheel.
471-8 SAAB Dec. 1975
Page 427
saae
PRESSING OUT THE OUTPUT GEAR FROM THE BEARING
Drift 839018, support 839009
6. If necessary, press the driver gear off the output
gear shaft using drift 839018 and tools 839009
and 839024 as supports (see illustration).
} é
PRESSING OFF THE DRIVER GEAR
Drift 839018, supports 839009 and 839024
7. Press the input gear complete with ball bearing out
of the bearing housing, using drift 839012, sleeve
839014 and support 839009 (see illustration).
peat Sus
$2452
PRESSING OUT THE INPUT GEAR WITH BEARING FROM
THE BEARING HOUSING
Drift 839012 and support 839009
8. Undo the lock ring from the input gear and press
the ball bearing off the gear, using supports
839009 and 839024 and drift 839018 (see illus-
tration).
$25
PRESSING THE INPUT GEAR OUT OF THE BEARING
Drift 839018, supports 839009 and 839024
9. Remove the bearing support that retains the gearbox
input gear (4th) with bearing (see illustration).
471-9
Page 428
a $2454
REMOVING THE BEARING SUPPORT
THE CLUTCH SHAFT SEAL LOCATION IN THE GUIDE SLEEVE
10. Press the gearbox input gear (4th) out of the prima-
ry gear housing, using ring 839021, drift 839018 13. If necessary, change the clutch shaft seal in the guide
and support 839009. Release the lock ring and press sleeve of the release bearing and press out the roller
the bearing off the shaft, using ring 839021, drift bearing (using tool 839032) for the input gear (clutch
839018 and supports 839009 and 839024 (see illus- shaft, see illustration).
tration).
PRESSING OUT THE ROLLER BEARING
Drift 839032, support 839009
PRESSING OFF THE BEARING
Ring 839021, drift 839018, supports 839009 and 839024
11. Press the free wheel shaft roller bearing out of the
primary gear housing, using tool 839022 and drift
839018.
12. _\f necessary, remove the oil seal ring from the pri-
mary gear housing.
471-10 SAAB Dec. 1975
—.)
Page 429
Assembling the primary gear unit
Having removed whichever Part needs attention, clean
the mating flange surfaces of the bearing housing and
Primary gear housing to remove gasket fragments and
traces of sealant compound. Inspect all disassembled
Parts and wash them in kerosene or similar.
Then reassemble as follows:
1, Fit the labyrinth seal, noting the marking, and the
oil seal ring if they have been removed, Then press
the free wheel shaft roller bearing into the primary
gear housing using drift 839010 and sleeve 839014
(see illustration).
32458
PRESSING ON THE BALL BEARING
Tools 839009, 839018, 839024 and 839029
PRESSING IN THE ROLLER BEARING
Tools 839010 and 839014
2. Press the ball bearing on to the gearbox input gear
(4th), using drift 839018, washer 839029 and sup-
ports 839009 and 839024 (see illustration). Fit the PRESSING IN THE GEAR WITH BEARING
\ y) bearing lock ring and press the gear-box input gear Tools 839009 and 839024
(4th) complete with bearing into the primary gear
housing, using tools 839009 and 839024 (see illustra- 3. Mount the bearing support for the ball bearing of
tion). the gearbox input gear (4th) to the primary gear
housing, securing the screws with Loctite.
NOTE
Use the intermediate gear shaft as a guide to locate
the bearing support correctly. The intermediate gear
thrust washer should be glued to the bearing support
to ease the job of mounting the intermediate gear
shaft. Make sure that the oil catcher is properly lo-
cated and held in position by the bearing support
(see illustration).
Dec. 1975 SAAB 471-11
— 7
Page 430
7. Press the primary input gear complete with ball
bearing into the bearing housing, using tools
839009 and 839024 (see illustration). The bearing
must be pressed in until it lies flush with the mating
surface of the bearing housing.
FITTING THE BEARING SUPPORT
4. Fit the needle bearing in the free wheel shaft if pre-
viously removed, using drift 839018.
5. Fit the free wheel drive hub in the free wheel shaft,
using tool 879030, and mount the free wheel shaft
in the primary gear housing. Fit the free wheel drive
control.
6. Press the ball bearing on to the input gear (for the
clutch shaft), using supports 839009 and 839024
and drift 839018. Fit the lock ring (see illustration). PRESSING ON THE GEAR AND BALL BEARING
Tools 839009 and 839024
8. Press the free wheel driver gear on to the output
gear shaft if previously removed, using supports
839009 and 839024 and drift 839018 (see illustra-
tion).
$3910
PRESSING ON THE BALL BEARING
Tool 839014
$2402
PRESSING ON THE FREE WHEEL DRIVER GEAR
Tools 839009, 839018 and 839024
471-12 SAAB Dec. 1975