Page 441
—
6. Remove the intermediate gear set (see illustration). Remove the shift shaft for the 1st—2nd gear 3rd-
top gear and shift forks and remove the shift fork
and sliding muff for 3rd—top gear.
NOTE
The reverse lever need not be undone from the gear
shift shaft when the shaft is removed.
REMOVING THE INTERMEDIATE GEAR SET
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.
8. Undo the reverse gear shift shaft retaining screw.
REMOVING THE SLIDING MUFF FOR 3RD — TOP GEARS a
9. Pull out the reverse gear shaft. Use tool 839004
to lift out the reverse gear.
10. Remove the needle bearing from the pinion shaft
and install too! 879050 as a lock for the reverse
gear (see illustration), and undo the pinion shaft
nut.
REMOVING THE REVERSE GEAR SHIFT SHAFT RETAINING
SCREW
Turn the gear selector rod so that the driver is de-
tached from the reverse gear shift and pull out the
shaft.
INSTALLING TOOL 879050
REMOVING THE REVERSE GEAR SHIFT SHAFT
Nov. 1971 SAAB 471-23
Page 442
11. Remove tool 879050 and remove the 3rd—top
gear synchronization hub and 3rd gear.
REMOVING 3RD GEAR
12. Undo the four pinion shaft bearing housing screws.
Install tool 879051 and press out the pinion shaft.
Put the gears, sleeves, washers and shims in a safe
place.
PRESSING OUT THE PINION SHAFT
Tool 879051
Differences in number of cogs and outer diameter (measured on the cogs) between transmissions up
to and incl. model 1972 and transmissions as from model 1973.
Transmission model 1972 Transmission as from model 1973
Primary gear Serial No. up to and incl. 437751 Serial No. as from 500.000
No. of teeth Outer diam. No. of teeth Outer diam.
Input gear 20 2.276" 20 2.318"
(57.8 mm) (58.9 mm)
Intermediate gear 48 5.151” 48 5.118”
(130.8 mm) (130.0 mm)
Output shaft 19 2.276" 20 2.318”
(57.8 mm) (58.9 mm)
Intermediate gear (tooth
surface engaged in first
gear) 17 2.224" 16 2.181"
(56.3 mm) (55.4 mm)
First gear 30 3.626” 30 3.665”
(92.1 mm) (93.1 mm)
Sliding wheel, reverse 14 1.890" 14 1.906”
(48.0 mm) (48.4 mm)
Reverse gear 34 4.166" 33 4.154"
(105.8 mm) (105.5 mm)
Pinion 9 2.077" 9 2.205"
(52.75 mm) (56.0 mm)
Crown wheel 38 6.914” 35 7.047"
(175.6 mm) (179.0 mm)
471-24 SAAB Sept. 1973
Page 443
Assembling the transmission
Having removed the component that needs attention,
clean all fragments of old gaskets and all traces of old
sealing compound off the covers and mating surfaces.
Inspect the transmission case and all disassembled parts
and wash them in kerosene or similar. Then reassemble
the transmission, following the procedure described be-
low:
1. Adjust the differential bearings to the correct com-
pression. See section 473.
2. Screw the two locating studs (tool 879043) into
the transmission case. Then shim and locate the
pinion shaft assembly. Tap the assembly gently
into position, using a plastic mallet, drift 839011
and sleeve 839014. Then insert and tighten the
four bearing housing screws.
MOUNTING THE PINION SHAFT
Locating studs 879043, drift 839011, sleeve 839014
NOTE
Any measuring or adjusting of the pinion shaft must
be done before the screws are secured with Loctite.
See section 473.
3. a. Before mounting the reverse gear on the pinion
shaft, the distance between the connecting sur-
face for the primary gear housing and the pinion
shaft nut must be checked. The distance must
be 7.677" —7.681" (195.0—195.1 mm). If it is
not this distance, shims must be placed between
Sept. 1973
MEASURING THE POSITION OF THE PINION SHAFT IN
THE GEARBOX HOUSING
the nut and the reverse gear. Shims are available
in thicknesses of 0.0118’ (0.30 mm), 0.0157”
(0.40 mm) and 0.0197” (0.50 mm). If the posi-
tion of the pinion shaft is unchanged, the shims
used earlier can be replaced.
b. When using measuring tool 879055, the proce-
dure of shimming is the following:
Install the measuring tool in the gearbox hous-
ing according to fig. and measure the distance
between tool and nut with the aid of a feeler
gauge. Fit shims with a thickness equvivalent to
that of the used feeler gauge.
>
MEASURING THE POSITION OF THE PINION SHAFT IN
THE GEARBOX HOUSING WITH THE AID OF TOOL 879055
4. Install the reverse gear using sleeve 839014.
SAAB 471-25
Page 444
INSTALLING THE REVERSE GEAR
Sleeve 839014
5. Fit the 1st gear on the bearing sleeve of the reverse
gear.
6. Fit 1st—2nd synchronization hub. Fit 1st—2nd
gear shift fork into 1st—2nd coupling muff and
mount these on the synchronization hub. Fit 1st—
2nd gear shift fork into 1st—2nd coupling muff
and mount these on the synchronization hub.
7. Install the 2nd gear sleeve with tool 839014 and
mount the 2nd gear on the sleeve.
8. Fit the spacer, mount the sleeve for 3rd gear with
tool 839014 and mount the 3rd gear on this sleeve.
INSTALLING SLEEVE FOR THE THIRD GEAR
Sleeve 839014
10.
Fit 3rd—4th gear synchronization hub. (As from
gearbox No, 500,001, the synchronization hub is
fitted with the three locking holes against the pinion
nut.) Fit 3rd—4th gear shift fork into 3rd—4th gear
coupling muff and mount these on the synchroniza-
tion hub.
Install tool 879050 at a lock for the reverse gear
and tighten the pinion shaft nut to the prescribed
torque of 29—49 Nm (22-36 ft.!b., 3-5 kpm)
and secure the nut. Install the pinion shaft needle
bearing and its locking ring. Remove tool 879050.
TIGHTENING THE PINION SHAFT NUT
11.
125
Ease the coupling muffs on the pinion shaft in the
neutral position and fit the gear shift shaft for
1st—2nd and 3rd—4th gear shift forks.
Turn the gear selector rod clockwise so that there
is room to mount the reverse gear shift shaft.
Mount the latter. Tighten the axle with the stop
screw.
The reverse lever can be fitted to the reverse gear
shaft before the shaft is mounted in the gearbox.
NOTE
Aug. 1973
|
tw
Page 445
i a at a eee aa
13. Mount the needle bearings in the intermediate gear
set with the help of grease so that they are held in
place until the intermediate gear set is fitted. Place
the intermediate gear set in the bottom of the gear-
box.
INSTALLING THE INTERMEDIATE GEAR SET
14. Check that the thrust washer for the intermediate
gear set is in the right place on the primary gear
housing. The washer can be glued on to facilitate
the fitting of the intermediate gear set. Check that
the connecting tube is fitted in the output shaft of
the primary gear.
Sept. 1973
FITTING THE CONNECTING TUBE IN THE OUTPUT GEAR
OF THE PRIMARY GEAR SET
15. Coat the mating flange of the primary gear housing
with sealant compound, e.g. Tikatat No. 2, and
screw the primary gear housing to the transmission
case.
NOTE
Leave the screws slightly slack to avoid jamming the
loose intermediate gear set in the wrong position be-
fore the intermediate gear shaft is inserted.
16. Ease the intermediate gear into its correct position
either by turning the transmission housing or by
lifting the intermediate gear. Fit the rear thrust
washer and push in the intermediate gear shaft,
using tool 839004.
471-27
Page 446
se
——4
ee
_———}
in
\
INSERTING THE INTERMEDIATE GEAR SHAFT
Tool 839004
17. Tighten the primary gear housing screws.
18. Install the reverse gear and shaft, making sure that
the reverse lever is fitted into the groove on the
reverse gear. Fit the lock plate over the reverse gear
and intermediate gear shaft ends. Secure the screw
with Loctite.
471-28 SAAB
INSTALLING THE REVERSE GEAR
19.
20.
21.
22.
23.
Insert the spring and ball catch for the gear selector
rod and fit the transmission housing cover together
with its gasket.
Install the differential assembly (see section 473).
Inspect the shaft seals in the differential bearing
seats and fit new ones if necessary. Adjust the
crown wheel backlash if necessary (see section 473).
Mount the two inner drive shafts complete with in-
ner universal joints, taking care not to damage the
shaft seals.
Fit the cover complete with gasket on to the trans-
mission case.
Fill the transmission case with oil (3 US qt, 5 Imp.
pints, 3 liters).
Sept. 1973
Page 447
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:
1. Fasten fixture 879063 and holder ring 879065 in a
vice. Put the pinion shaft in the tool and loosen the
nut with the aid of tool 879045,
PRESSING THE REAR BEARING OFF THE SHAFT
Tools 879063 and 879065
4. Press the outer rings of the conical roller bearings out
of the bearing housing using tools 839009, 839010
and 839014 (see illustration).
REMOVING THE PINION BEARING NUT
Tools 879063, 879065 and 879045
2. Put the unit in a press and press off the front roller
bearing with the help of sleeve 839009, see illustra-
tion.
TOOLS 839010, 839014 AND 839009
PRESSING THE SHAFT OUT OF THE BEARING HOUSING PINION SHAFT WITH BEARING, BEARING HOUSING AND
Too! 839009 SPACER SLEEVE
The washer between the pinion gear and the rear bearing occurs
3. Press off the rear roller bearing with the aid of tools only on gearboxes with serial numbers lower than 500.000.
879063 and 879065.
Dec. 1975 SAAB 471-29
Page 448
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: Kf
4,
NOTE 5.
The bearings must be oiled before being assembled.
1. Press the outer races of the tapered roller bearings
into the bearing housing, using tools 839018 and
879046.
6.
INSTALLING THE BEARING RACE IN BEARING HOUSING 7.
Tools 839018 and 879046
2. Fit the spacer washer (only valid for gear boxes
with serial numbers lower than 500.000), and press
on the roller bearing nearest the pinion gear until
it butts against its stop, using tool 839014 (see
illustration).
——
7
PRESSING ON THE ROLLER BEARING NEAREST THE
PINION GEAR
S339
Tool 839014
As from gear box No. 401651 a collapsible spacer
has been incorporated on the pinion shaft. This
collapsible spacer is to be used when overhauling
pinion shafts of the earlier type.
Fit the spacer on the shaft.
Fit the bearing housing.
Fit the front roller bearing.
PRESSING IN THE FRONT ROLLER BEARING
Tool 839014
Set up the shaft in a press (see illustration). Press
the bearing housing slowly on, using tool 839014,
and twist it at the same time until resistance to
twisting is felt.
Smear Loctite “stud lock’ on the threads and put
on the nut. Install the pinion shaft in a vice with
fixture 879063 and holder ring 879065. As alterna-
tive, tool 839006 (see illustration), or tool 879044
can be used, depending on shaft design. Pull the nut
with key 879045 until the correct torque is obtained.
Measure the torque by pulling the bearing housing
with the aid of a dynamometer 839013. The bear-
ings should be lightly oiled and tightened as follows:
New bearings 47—70 N (10—15 Ib., 4.7—7.0 kp) on
CHECKING THE BEARING HOUSING TORQUE
Tools 839006 and 839013
Dec. 1975
Page 449
the dynamometer which corresponds to a torque of Removing the primary gear housing
2.5+0.5 Nm (2 +0.5 ft.lb., 25 + 5 kpem). Old
bearings that have done more than 1.200 miles To remove the primary gear housing, follow the instruc-
(2.000 km) 19—43 N (4.2—9.5 Ib., 1.9—4.3 kp) tions already given for disassembling the transmission.
dynamometer reading which corresponds to a tor- According to these, the differential assembly must be
que of 1.3 +0.5 Nm (1 + 0.5 ft.lb., 13 + 5 kpcem). removed and the intermediate gear set freed before the
When the correct value is obtained, upset the flange primary gear housing can be separated from the trans-
of the nut with a drift. mission case.
Disassembling
1. Separate the bearing housing from the primary gear
case (see illustration).
OPENING THE PRIMARY GEAR HOUSING
NOTE
LOCKING THE PINION BEARING NUT Remember to undo the clutch adjustment nut. |
8. Fit two locating pins, tool 879043, in the gearbox
housing. Then fit on the shims and mount the pin-
ion shaft with bearing housing. Knock the bearing
housing carefully into place using a plastic mallet
or hammer together with drift 839011 and sleeve
839014. Then tighten the four screws.
NOTE
Any measuring or adjusting of the pinion shaft must
be done before the screws are secured with Loctite.
See section 473.
PRIMARY GEAR TRAIN
1, Input gear
2. Center wheel
3. Output gear
Sept. 1973 SAAB 471-31
Page 450
2. Remove the center wheel shaft from the bearing
housing and back off the center shaft nut so that
the center wheel can be taken off.
3. Press the outer races of the tapered roller bearings
out of the center wheel with drift 839018 and
sleeve 879047, using tool 839009 as a support.
PRESSING OUT THE GEAR
Tools 839018 and 839009
4. Remove the cap from the bearing housing, free the
lock ring from the shaft and press the Output gear
out of the bearing, using too! 839009 as a support
and pressing with drift 839018 (see illustration).
Then press the bearing out of the bearing housing.
Use tools 839018 and 879046 (see illustration).
res
8.
PRESSING OUT THE BEARING FROM THE BEARING
HOUSING
Tools 839018 and 839046
5. Press the input gear complete with ball bearing out
of the bearing housing, using drift 839012, sleeve
839014 and support 839009 (see illustration).
471-32 SAAB
$2452
PRESSING OUT THE INPUT GEAR
Tools 839012, 839014 and 839009
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 illustra-
tion).
$3395
PRESSING THE BEARING OFF THE INPUT GEAR
Tools 839018, 839009 and 839024
Remove the bearing support that retains the gear-
box input gear (4th) with bearing.
Press the gearbox input gear (4th) out of the pri-
mary gear housing, using ring 839021 and drift
839018. Release the lock ring and press the bearing
off the shaft, using ring 839021 and drift 839018.
Dec, 1975
w~~