Page 431
ve
9. Press the output gear ball bearing into the bearing 12. Press the input gear roller bearing into the primary
housing, using supports 839011 and 839024. gear housing if previously removed, using tool
Then press the output gear into the ball bearing, 839032.
using supports 839009 and 839024 (see illustration). 13. Coat the bearing housing sealing surface and cap with
Then fit the washer and lock ring. sealant compound, e.g. Tikatat 2, and fit the bearing
housing to the primary gear housing. Secure the
bearing housing to the primary gear housing and the
cap to the bearing housing.
14, Fit a new seal ring in the release bearing guide sleeve
if necessary.
15. Mount the primary gear housing on the transmission
case.
Clutch shaft sealing ring
Changing the clutch shaft sealing ring
e Removal
Remove clutch, clutch disc, release bearing and guide
sleeve. See description on page 411—2.
Remove the sealing ring from the guide sleeve with for
4 example a screw driver.
erga Assembly
PRESSING THE OUTPUT GEAR INTO THE BALL BEARING
eo S208 and.839024; Fit the sealing ring in the guide sleeve with aid of tool
839032 (see illustration). Fit clutch, clutch disc, release
10. Fit the inner roller bearing to the center gear shaft, bearing and guide sleeve. See description on page 411—2.
using sleeve 839014 if necessary. Then mount the
center gear and outer roller bearing plus the friction
wheel if this has previously been removed.
11. Set up the center wheel, shaft and bearing in a vise.
Wind a cord round the gear wheel and rotate the
wheel with a dynamometer 839013 (see illustration).
Tighten and lock the nut when the dynamometer
reading reaches 6.0—8.0 N (1.32—1.76 Ib., 0.6—0.8
. kp), which corresponds to a torque of 0.4—0.5 Nm
) (3.5—4.3 in.Ib., 4.0—5.0 kpcm). Use wrench
ce 839019 to tighten the lock nut. Then mount the
center wheel in the bearing housing.
,
S 1830 $3211
COMPRESSING THE CENTER SHAFT BEARINGS FITTING THE CLUTCH SHAFT SEALING RING
Too! 839013 Tool 839032
Dec. 1975 SAAB 471-13
Page 432
Free wheel
Free wheel hub
If the free wheel hub has to be disassembled for repair, it
is usually sufficient to renew the hub and rollers. If the
free wheel shaft sleeve is damaged, however, the free wheel
shaft must be exchanged as a unit.
Removal and installation
The power plant doesn’t need to be lifted out when re-
moving the free wheel.
Remove the hood (see page 201—1).
Loosen the battery cables and lift out the battery.
Drain off the coolant.
Undo the cable connections to radiator fan, ther-
mostat contact, headlamps and headlamps cleaner
motor.
5. Detach the radiator hoses.
6. Undo the four fastening screws from the front
sheet.
7. Remove the headlamp decor frames.
8. Remove the four lower screws securing the head-
lamps (two screws for each headlamp).
9. Detach the hood lock operating cable.
10. Remove the front sheet.
11. Remove the front engine bracket. (As from model
1970.)
12. Undo the three exhaust pipe screws.
13. Detach the throttle contro! linkage and the throttle
control damper.
14. Raise the power plant about 4’’ (100 mm) in the
pro dS lee
front end.
15. Remove the lock ring and the clutch shaft sealing
cover.
16. Remove the clutch shaft center screw with washer
and O-ring.
17. Fit the tapping hammer 839027 and the joint
839001 in the clutch shaft end. Then carefully pull
out the clutch shaft.
18. Separate the primary gear case from the bearing
housing.
19. a, Insert wrench 879032 into the splines of the
free wheel drive hub and twist the hub to the
right, pulling the hub outward at the same time
until the rollers project for halt their length.
b. Fit the sleeve 879031 over the rollers on the hub
and keep the tool pressed against the free wheel
shaft. Continue to twist the hub to the right
with the wrench and at the same time pull the
hub into the tool sleeve.
Reassemble in the reverse order.
Disassembling the free wheel hub
1. Place a clean rag over the free wheel hub and tool
sleeve to prevent the rollers and springs from being
thrown out on to the floor.
2. Push the hub out of the sleeve.
3. Clean the hub and rollers with paraffin oil.
471-14
Assembling
1. Set up the sleeve of tool 879030 in a vise (see illustra-
tion).
2. Orient the hub so that the figures will face inward
when the hub is mounted in the free wheel sleeve.
3. Insert the key to tool 879030 into the splines of the
hub, and place the hub in the tool sleeve (see illustra-
tion).
PLACING THE HUB IN THE TOOL \
Tool 879030 2
4. Insert the springs, plungers and rollers. Turn the hub
to the left with the key, and at the same time, using
the thumb, push down the roller against the springs,
until the roller slips under the edge of the tool sleeve.
The installation is made easier if two rollers, facing
each other, are put in. Then place the hub in the sleeve
for centering.
5. When all the rollers have been inserted, turn the hub
just enough to hold the last one in place in the sleeve —
otherwise the first one will jump out again.
INSERTING THE ROLLERS
Tool 879030
Dec. 1975
Page 433
6. In this position, slide the hub into the unrecessed end
of the tool sleeve, letting the rollers project for half
their length so that they will slip easily into the
free wheel drive sleeve. This locates the hub in rela-
tion to the sleeve. Push and at the same time twist the
hub to the right with aid of the wrench, to seat the hub
in the free wheel drive sleeve.
Primary gear
The power plant doesn’t need to be lifted out when re-
moving the primary gear.
Removal
1. Remove the hood (see page 201—1).
2. Loosen the battery cables and lift out the battery.
3. Drain off the coolant.
4. Undo the cable connections to radiator fan, ther-
mostat contact, headlights and headlight wiper mo-
tor,
Detach the radiator hoses.
6. Undo the four fastening screws from the front
sheet.
7. Remove the headlight trim frames.
8. Remove the four lower screws securing the head-
lights (two screws for each headlight). As from the
1972 model the headlights are disconnected from
the front sheet and the body.
9. Detach the hood lock operating cable.
10. Remove the front sheet.
11. Remove the front engine bracket. (As from model
1970.)
12. Undo the three exhaust pipe screws.
13. Detach the throttle control linkage and the throttle
control damper.
14. Raise the power plant about 4” (100 mm) in the
4
front end.
15. Remove the lock ring and the clutch shaft sealing
cover.
16. Remove the clutch shaft center screw with washer
and O-ring.
17. Fit the tapping hammer 839027 and the joint
839001 in the clutch shaft end. Then carefully pull
out the clutch shaft.
18. Detach the free wheel cable and separate the pri-
mary gear case from the bearing housing, see illus-
tration.
Dec. 1975
OPENING THE PRIMARY GEAR HOUSING WITH THE
POWER PLANT INSTALLED IN THE CAR
NOTE
Remember to undo the clutch adjustment nut.
19.
20.
If necessary remove the free wheel control.
Remove the center wheel shaft from the bearing
housing and back off the nut using too! 839019
so that the center wheel can be taken off. Then
press the inner ring off the shaft using tool 839014.
If necessary, remove the friction wheel from the
center wheel.
471-15
Page 434
PRIMARY GEAR TRAIN
1. Input gear
2. Center wheel
3. Output gear
$3182
CENTER WHEEL OF PRIMARY GEAR ASSEMBLY WITH
SHAFT AND BEARINGS
21. 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 support
and pressing with drift 839018 (see illustration).
Then press the bearing out of the bearing housing
using too! 839012 and sleeve 839014.
471-16
~t
cl
| )
PRESSING OUT THE OUTPUT GEAR FROM THE BEARING
Drift 839018, support 839009
22. \f necessary, press the driver gear off the output
gear shaft using drift 839018 and tools 839009
and 839024 as supports (see illustration).
p)
Besant
PRESSING OFF THE DRIVER GEAR
Drift 839018, supports 839009 and 839024
23. Press the input gear complete with ball bearing out
of the bearing housing, using drift 839012, sleeve
839014 and support 839009 (see illustration).
SAAB Dec. 1975
Page 435
$2482
PRESSING OUT THE INPUT GEAR WITH BEARING FROM
THE BEARING HOUSING
Drift 839012, sleeve 839024, support 839009
24. 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).
$2453
PRESSING THE INPUT GEAR OUT OF THE BEARING
Drift 839018, supports839009 and 839014
Jan. 1973
Assembly
1, Fit the free wheel drive control if this previously
has been removed,
2. Press the ball bearing on to the primary gear train
input gear, using sleeve 839014.
sasi0
PRESSING ON THE BALL BEARING
Sleeve 839014
3. Press the input gear complete with ball bearing in-
to 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.
~ As 3911
PRESSING ON THE GEAR WITH BALL BEARING
Sleeve 839004, ring 839024
SAAB 471-17
Page 436
4. Press the free wheel driver gear on to the shaft if
previously removed, using supports 839009 and
839024 and drift 839018.
saz
PRESSING ON THE FREE WHEEL DRIVER GEAR
Drift 839018, supports 839009 and 839024
5. Press the output gear ball bearing into the bearing
housing, using supports 839009 and 839024. Then
press the output gear with shaft into the ball bear-
ing, using supports 839009 and 839024 (see illus-
tration). Then fit the washer and lock ring.
PRESSING THE OUTPUT GEAR INTO THE BALL BEARING
Supports 839009 and 839024
471-18 SAAB
6. Fit the inner roller bearing to the center wheel
shaft, using sleeve 839014 if necessary. Then
mount the center gear and outer roller bearing
plus the friction wheel if this has previously been
removed,
7. Set up the center wheel, shaft and bearings in a
vice. Wind a cord round the gear wheel and rotate
the wheel with a dynamometer (see illustration).
Tighten and lock the nut when the dynamometer
reading is 6.0—8.0 N (1.32—1.76 Ib., 0.6—0.8 kp)
which corresponds to a torque of 0.4—0.5 Nm
(3.5—4.3 in.lb., 4.0—5.0 kpcm). Use wrench
839019 to tighten the lock nut. Then mount the
center wheel in the bearing housing.
51830
COMPRESSING THE CENTER SHAFT BEARINGS
Dynamometer 839013
8. Press the input gear roller bearing into the primary
gear housing if previously removed, using tool No.
839032.
9. Coat the bearing housing sealing surface and cap
with sealant compound, e.g. Tikatat 2, and fit the
bearing housing to the primary gear housing. Secure
the bearing housing to the primary gear housing
and the cap to the bearing housing.
10. Fit the clutch shaft.
11, Fit the clutch shaft center screw with washer and
O-ring.
12. Fit the clutch shaft sealing cover and its lock ring.
13. Fit the front engine bracket and low the power
plant. Tighten the engine bracket nut.
14. Adjust the clearance between diaphragm spring
and release bearing with the adjusting screw and
then tighten the lock nut.
15. Fit the throttle control linkage.
16. Fit the exhaust pipe.
17. Fit the free wheel cable.
18. Fit the front sheet and the radiator. Connect the
radiator hoses.
19. Connect the electrical cables and fit the battery.
20. Fill the radiator with coolant.
21. Fit the engine hood.
22. Check the headlight alignment.
Dec. 1975
Page 437
Gear shift mechanism
The gear shift mechanism consists of gear shift forks,
shafts and a selector rod with spring-loaded ball catch.
A stronger detent with a flange 0.35’ (9 mm) thick has
been introduced with effect from transmission No, 15792.
Gear shift forks for 1st—2nq and 3rd—4th gears
adapted to the new detent have also been introduced
at the same time.
If the detent or a gear shift fork needs to be exchanged,
both the detent and the mentioned gear shift forks must
be changed together. Components of the earlier design
are no longer stocked as spares. The new components are
listed in the Spare Parts Catalogue.
1
9 mm (0.38"1
2
$3184
DETENT, GEAR SHIFT FORKS
1. Detent
2. Gear shift fork 1st and 2nd
3. Gear shift fork 3rd and 4th
Disassembling
Clean off the transmission case and drain the oil.
1. Take off the rear cover from the differential housing
and remove the inner universal joints with drive shafts.
2. Remove the differential assembly by unscrewing the
right and left differential bearing seats. Take out the
differential assembly. Put aside the shims, if any, for
reassembly later.
3. Remove the lock plate that holds the intermediate and
reverse gear shafts and pull the intermediate gear shaft
using tool 839004, leaving the intermediate gear set
loose in the transmission case.
Separate the primary gear housing from the transmis-
sion case and lift it off.
>
Dec. 1975
5. Unscrew the side cover from the transmission case.
Take out the ball catch and spring for the gear selector
rod and put them in a safe place. Pull both the gear
shift shafts and lift out the gear shift forks. If the se-
lector rod assembly or any part of it is to be exchanged,
use a drift or similar tool to knock out the tension pin.
GEAR SHIFT SHAFTS AND FORKS
Assembling
Before beginning to reassemble the gear shift mechanism,
clean the mating flange surfaces of the transmission case
and covers to remove fragments of old gaskets and traces
of sealant compound.
1, Place the coupling muffs in neutral, engage the gear
shift forks and fit the two gear shift shafts.
2. Coat the mating flange of the primary gear housing with
sealant compound, e.g. Tikatat 2, and mount the pri-
mary gear housing on the transmission case.
NOTE
Draw the screws hand tight only, to avoid jamming
the intermediate gear set in the wrong position be-
fore the intermediate gear shaft is inserted.
3. Lift the intermediate shaft gear with the hook
wrench 839019 and fit the intermediate shaft. Use
tool 839004 and sleeve 839026.
4. Tighten the primary gear housing screws.
471-19
Page 438
INSERTING THE INTERMEDIATE SHAFT GEAR UNIT
Too! 839019
5. Fit the reverse gear, the ball, the spring and the
lever. Coat the cover with sealant compound, e.g.
Tikatat 2 and then fit the cover.
6. Fit the lock plate for the intermediate and reverse
gear shafts.
7. Fit the differential assembly.
8. Check the shaft seals in the differential bearing seats
before mounting them. Use arbor 839032 to fit new
seals if required. Then insert both inner drive shafts
complete with inner universal joints, taking care not
to damage the shaft seals.
9. Coat the rear cover of the differential housing with
sealant compound, e.g. Tikatat 2, and screw the
cover to the transmission case.
10, Fill the transmission with oil (3 US qt, 5.5 Imp.pints,
3.0 liters).
Speedometer drive
Removal and installation
1. Disconnect the speedometer cable from the transmis-
sion.
2. Unscrew and remove the bearing sleeve with shaft and
gear. Save the gasket.
3. Knock out the tension pin that retains the gear on the
shaft, after which the gear, shaft and bearing sleeve
can be taken apart. Exchange any damaged or worn
parts.
Reassemble in the reverse order.
Friction brake
General
The center gear wheel in the primary gear assembly of
some gearboxes has a friction brake, the function of
which is to eliminate gear backlash and thereby reduce
noise.
The device consists of a friction wheel with two more
teeth than the center gear wheel; it therefore rotates
slowly with respect to the latter. As the friction wheel
is spring loaded, it exerts enough retarding force to pre-
vent backlash between the primary input gear and the
output gear.
471-20
Directions for fitting
When fitting the friction brake, check that the teeth make
contact with the center gear wheel at an angle of 4° and
that the tops of the spring spokes are at the correct dis-
tance from the plane of contact (see illustration).
$2243
A = 0.26—0.276" (6.5—7.0 mm)
B=4°
FRICTION WHEEL
MOUNTING THE FRICTION WHEEL
Synchronization
Synchronizing rings
If the synchronization is to work properly, the synchro-
nizing rings must mate properly with the cones.
When a synchronizing ring is mounted, there must be a
gap of at least 0.04” (1 mm) between it and the coupling
teeth. If not, the ring should be exchanged for a new one.
NOTE
Up to gearbox No. 38.686 the synchronizing ring
for first gear is of special design. It can be told apart
from the others by the fact that it lacks three teeth.
Dec. 1975
Page 439
4
f
2
.
3.3185
8
SYNCHRONIZATION, 1ST AND 2ND GEARS UP TO GEAR
GEARBOX NO. 38.686
1. 1st gear 6. Driver
2. Guide ring 7. Spring
3. Spring ring 8. Synchronizing ring
4. Synchronizing muff
5. Synchronizing hub
9. 2nd gear
With effect from gearbox No. 38.687 a new type of syn-
chronization has been introduced for the 1st and 2nd
gears. The new design features larger synchronizing rings
working against a female cone in the synchronizing muff.
The arrangement of the new synchronization is shown in
the figure.
Note that the 1st gear spring gives a lower pressure than
the 2nd gear spring. The 1st gear spring is copper-colored
so that the two can easily be distinguished from each
other. The springs are to be placed on the gears in such
a way that there are five teeth between the ends of the
springs.
The procedure for removing the gears from the pinion
shaft and reassembling them remains the same as before.
Soi
SYNCHRONIZATION, 1ST AND 2ND GEARS AS FROM
GEARBOX NO. 38.687
1. 1st gear 6. Synchronizing hub
2. Guide ring 7. Synchronizing muff
3. Retaining spring, 1st gear 8. Retaining spring, 2nd gear
4. Synchronizing ring 9. 2nd gear
5. Lock ring
:
$3186
Nov. 1971 SAAB 471-21
Page 440
—_-
Manual transmission as from chassis No. 99722003499
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.
REMOVING THE LOCKING PLATE
Disassembling the transmission
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 the inner universal joints using puller
879035 and tapping ham mer 839027. Remove
the cover from the differential housing.
3. Remove the differential assembly by unscrewing the
differential bearing seats on both sides and removing
them with the help of puller 839147 and tapping
hammer 839027. Take out the differential assem-
bly with shims (if any). Safe the spacer washers and
shims; the latter must be replaced in their original
sass
REMOVING THE INTERMEDIATE GEAR SHAFT
Tool 839004
5. Separate the transmission at the joints between
the gearbox and primary gear housing and lift away
the primary gear housing (see illustration).
REMOVING THE DIFFERENTIAL ASSEMBLY
positions on reassembly unless the differential gear
backlash has been altered by the exchange of some
component. Before disassembling the differential, read
section 473,
4. Remove the locking plate that holds the interme-
diate and reverse gear shafts in place (see illustra-
tion). Use too! 839004 to withdraw the interme-
diate gear shaft so that the intermediate gear set
drops down. =!
SEPARATING THE PRIMARY GEAR HOUSING FROM THE
GEARBOX
471-22 SAAB Sept. 1973