Page 451
Assembly
Having removed whichever Part needs attention, clean
the mating flange surfaces of the cover 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 needle bearing with too! 879047 and drift
839018, and the oil collector into the primary
gear housing if they have been removed.
2. Press the ball bearing on to the input gear of the
gearbox (4th), using sleeve 879048. Fit the bear-
$3381
REMOVING THE BEARING FROM THE INPUT GEAR
Drift 839018, ring 839021
9. If necessary, remove the oil collector and needle
bearing from the primary gear housing.
MOUNTING THE BEARING ON THE INPUT GEAR
Sleeve 879048
ing lock ring and press the gear box input gear (4th)
completle with bearing into the primary gear hous-
ing, using tool 839012.
REMOVING THE NEEDLE BEARING
10. Press out the input gear roller bearing from the pri-
mary gear housing, using tool 839032 and support
839009 (see illustration).
ny ¢ i $3385
MOUNTING THE INPUT GEAR AND ITS BEARING INTO
THE PRIMARY GEAR HOUSING
Sleeve 839012
REMOVING THE ROLLER BEARING
Drift 839032, support 839009
SAAB 471-33
Jan. 1973
Page 452
3. Mount the bearing support for the ball bearing of
the gearbox input gear to the primary gear housing,
securing the screws with Loctite.
4. Press the ball bearing on to the input gear of the
primary gear unit, using sleeve 839014, see illustra-
tion. Fit the lock ring.
$3296
FITTING THE OUTPUT GEAR INTO THE BEARING HOUSING
$310 Support sleeve 879048
PRESSING ON THE BALL BEARING, SLEEVE 839014 7. Fit the outer roller bearing race in the center wheel,
5. Press the primary input gear complete with ball using tool 839032.
bearing into the bearing housing, using sleeve
839009 and ring 839024 and a suitable support
between the sleeve and the press head. The bear-
ing must be pressed in until it lies flush with the
mating surface of the bearing housing.
FITTING THE BEARING RACE IN THE CENTER WHEEL
Drift 839032
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PRESSING IN THE GEAR AND BALL BEARING IN THE
BEARING HOUSING 8. Fit the front roller bearing on to the center wheel
Sleeve 839009 and ring 839024 shaft. Then fit the center wheel and the outer roller
bearing.
9. Set up the center wheel complete with shaft and
bearing in a vice. Wind the cord round the cog-
wheel and pull the wheel round with a dynamo-
meter (see illustration).
6. Press the output gear ball bearing into the bearing
housing, using tools 839014 and 839011. Then
press the output gear into the ball bearing, using
sleeve 879048 as support (see illustration). Then
fit the washer and lock ring.
471-34 SAS Jan. 1973
Page 453
Assembly
Fit the sealing ring in the guide sleeve using tool 839032
(see illustration). Fit clutch, clutch plate, release bearing
and guide sleeve. See description on page 411-2.
MEASURING THE TORQUE OF THE CENTER WHEEL
Dynamometer 839013
Tighten and secure the nut with Loctite and upset
the flange of the nut with a drift when the dynamo-
meter reading is 6—8 N (1.3—1.8 Ib., 0.6—0.8 kp)
which corresponds to a torque of 0.4—0.5 Nm (3—
4 in.lb., 4—5 kpcm).
10. Fit the center wheel into the bearing housing and
tighten the screw and secure it with Loctite.
11, Press in the primary input gear roller bearing into
the primary gear housing if it has been removed,
using tool No. 839032.
12. Coat the flange of the bearing housing with a sealing
compound, for example Tikatat No. 2, and fit the FITTING THE CLUTCH SHAFT SEALING RING
bearing housing into the primary gear housing. Drift 839032
Tighten the bearing housing cover.
13. Mount the primary gear housing on to the gearbox
and follow the instructions for assembly of the
gearbox.
$3211
Clutch shaft sealing ring
Changing the clutch shaft sealing ring
Removal
Remove clutch, clutch plate, release bearing and guide
sleeve, See description on page 411-2.
Remove the sealing ring from the guide sleeve with, for
example, a screwdriver,
Jan. 1973 SAAB - 471-35
Page 454
Gear shift mechanism
The gear shift mechanism consists of gear shift forks,
shafts and a selector rod with a spring-loaded ball catch.
Disassembling
. Clean off the transmission case and drain the oil.
2. Take off the cover from the differential housing and
remove the inner universal joints with guide shafts.
3. 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.
os
DISASSEMBLING THE DIFFERENTIAL
4. Remove the lock plate that holds the intermediate
and reverse gear shafts and pull out the intermediate
gear shaft, using tool 839004, so that the intermedi-
ate gear drops out.
REMOVING THE LOCK PLATE
471-36
Mt
+
S384
REMOVING THE INTERMEDIATE GEAR SHAFT
Tool 839004
5. Separate the primary gear housing from the transmis-
sion case and lift it off. Remove the intermediate gear.
SEPARATING THE PRIMARY GEAR HOUSING FROM THE
TRANSMISSION CASE
6. Unscrew the transmission side cover, take out the
spring and ball catch for the gear selector rod, and
put them in a safe place.
REMOVING THE GEAR SELECTOR ROD SPRING
SAR Jan. 1973
Page 455
ww
7. Undo the reverse gear shift shaft retaining screw. Turn
the gear selector rod to free the driver from the re-
verse gear shift and pull out the shaft.
REMOVING THE REVERSE GEAR SHIFT SHAFT RETAINING
SCREW
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‘sx090
GEAR SHIFT MECHANISM FOR REVERSE GEAR
8. Remove the locating stud for the paw! shaft and re-
move the latter by withdrawing it from the gear se-
lector rod. The gear selector rod can be removed from
the transmission case without the driver being taken
away. The cotter pin in the driver can then be re-
moved by using a drift or similar tool.
REMOVING THE REVERSE GEAR SHIFT SHAFT
Remove the shift shaft for the 1st—2nd gear and 3rd—
top gear shift forks together with the shift fork for
3rd—top gear.
NOTE
The reverse lever need not be undone from the gear
shift shaft when the shaft is removed, but can be re-
moved afterwards by undoing the screw which holds
the reverse lever to the shaft.
REMOVING THE COTTER PIN FROM THE DRIVER
9. If the gear shift fork for 1st—2nd gear has to be re-
moved, the pinion shaft must be removed (see section
on disassembling the transmission).
Assembling
1. Install the pinion shaft, shims and reverse gear, 1st
gear and synchronizing hub. Fit 1st—2nd gear shift
fork into 1st—2nd gear coupling muff and mount
these on to the synchronizing hub. Install sleeve
and 2nd gear,spacer and sleeve and 3rd gear and
Nov. 1971 Senses 471-37
Page 456
3rd—4th gear synchronizing hub. (As from gearbox
No. 500.001 the synchronization hub locking holes
are turned against the nut.) Put 3rd—top gear shift
fork into 3rd—top gear coupling muff and mount
these on to the synchronizing hub. Smear Loctite
on the threads and tighten the pinion shaft nut to
a torque of 29—49 Nm (22-36 |b.ft., 3—5 kpm)
and secure it. Install the needle bearing and lock
ring on to the pinion shaft.
2. Fit the driver to the gear selector rod and mount
the latter in the transmission case. Install the pawl
shaft on the gear selector rod and fit the locating
stud. See to it that the locating stud is correct
located or the gear shift rod can be jammed.
INSTALLING THE REVERSE GEAR SHIFT SHAFT
FITTING THE LOCATING STUD
3. Slide the coupling muffs on the pinion shaft to
5.
Fit the needle bearing into the intermediate gear
with the help of grease so that it will be held in
place until the intermediate gear shaft is installed.
Then place the intermediate gear set in the bottom
of the transmission case.
their neutral position and fit the gear shift shaft INSTALLING THE INTERMEDIATE GEAR SET
for 1st—2nd gear and 3rd—top gear shift forks.
4. Fit the bearing sleeve and reverse lever to the re- 6.
verse gear shift shaft and tighten the screw.
83300
GEAR SHIFT MECHANISM FOR REVERSE GEAR
Fit the reverse gear shift to the shaft. Turn the
selector rod clockwise so that there is room to
mount the reverse gear shift shaft. Mount the lat-
ter. Make sure that the reverse lever engages the
Make sure that the thrust washer for the intermedi-
ate gear is in the correct place in the primary gear
housing. The washer can be glued in place to faci-
litate the installing of the intermediate gear. Check
also that the connecting tube is fitted into the out-
put shaft of the primary gear.
groove on the reverse gear. INSTALLING THE CONNECTING TUBE
Tighten the shaft with the stop screw.
471-38 SAAB
Jan. 1973
Page 457
7. Coat the flange of the primary gear housing with a
sealant compound, e.g. Tikataét No. 2, and fit the
primary gear housing on to the transmission case.
NOTE
Leave the screw slightly slack to avoid jamming
the loose intermediate gear set in the wrong posi-
tion before the intermediate shaft is inserted.
8. 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.
9. Fit the lock plate over the reverse gear and inter-
mediate gear shaft ends. Secure the screw with
Loctite.
10. Tighten the primary gear housing screws.
11. Insert the spring and the ball catch for the gear
selector rod and mount the transmission case side
cover together with its gasket.
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ees. : $3389,
FITTING THE SPRING FOR THE GEAR SELECTOR ROD
12. Install the differential assembly (see section 473).
13. 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 inner universal joints taking care not to dam-
age the shaft seals.
14. Fit the cover complete with gasket to the trans-
mission case.
15. Fill the transmission case with oil (3 US qt, 5
Imp.pints, 3 liters).
Changing the sealing ring, gear shift rod
Can be done in car or on a removed gearbox.
Removal
1. Knock off the front taper pin from the gear shift
joint and separate the joint from the rod.
2. Pull off the rubber bellows from the collar on the
sealing ring.
3. Put the removing tool 879067 over the collar on the
sealing ring and screw in the screw of the tool against
the shaft.
Jan. 1973
REMOVING TOOL 879067
4. Pry off the sealing ring with the aid of a screwdriver
held between the tool and one of the screw heads on
the rear cover.
Installation
1. Fit the new sealing ring with the aid of installing tool
879068 and a suitable hammer.
INSTALLING TOOL 879068
2. Fit the rubber bellows on the sealing ring.
3. Put together the gear shift rod joint and the gear shift
rod and fit the taper pin.
Synchronization
Synchronizing rings
When changing the synchronizing rings, follow the instruc-
tions for the dismantling of the gear box. The differential
unit must be removed and the intermediate gear discon-
nected so that the primary gear housing can be removed.
When changing the synchronizing ring for top gear, no
SAAB 471-39
Page 458
further dismantling is necessary.
When changing the synchronizing ring for 1st and 2nd
gear, the pinion shaft must be taken out of the transmis-
sion housing, so that the gears can be removed from the
shaft.
Disassembling
The synchronizing ring is removed by undoing the lock
ring which attaches the synchronizing ring to the gear.
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SYNCHRONIZATION, 1ST AND 2ND GEARS
123456 =
1. 2nd gear
2. Guide ring
3. Retaining spring, 2nd gear
4. Synchronizing ring
5. Lock ring
6. Synchronizing hub
7. Coupling muff
8. Retaining spring, 1st gear
9. 1st gear
REMOVING THE SYNCHRONIZING RING FOR 3RD GEAR
Assembling
First fit the guide rings for the retaining springs, and the . =
lock rings for the guide rings on 3rd and 4th gear. First
and second gear have no lock rings for the guide rings.
The retaining spring is fitted with a long wire end nearest
the guide ring, and the spring is placed so that there are
eleven teeth between the ends of the spring. The synchro-
nizing ring is placed so that the ends of the retaining
spring fit into the spaces between the teeht, after which
the lock ring is fitted.
: 1 3 45 6
SYNCHRONIZATION, 3RD GEAR
1, Lock ring
2. Synchronizing ring
3. Retaining spring, 3rd gear
4. Guide ring
5. Lock ring for guide ring
6. 3rd gear
ae = ls $3404
POSITIONING OF A SPRING END IN THE SPACE BETWEEN
THE TEETH OF THE RING
471-40 SAAB Jan. 1973
Page 459
BLEEDER, EARLIER DESIGN
Jan. 1973
BLEEDER, LATER DESIGN
471-41
Page 460
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