Page 471
FITTING TORQUE CONVERTER HOUSING
17. Mount the indicator dial 784062 in holder 879006
and prize up under the planet carrier with a screw-
driver. The play should be 0.01—0.03” (0.25—0.75
mm); if it is not within these limits, adjust by shim-
|
ming between the ring gear and the forward sun
gear, or between the washer and bearing on the in-
put shaft.
S
|
\
\ MEASURING THE PLAY
| \ Tools 784062 and 879006
|
|
if
\ 18. Mount the torque converter and oil pump. This
| must be done with great care to avoid damaging
] the seal ring. Tap the pump housing with a plastic
. mallet and tighten the screws.
Dec. 1975
Check that the pressure pipe from the pump to
the valve housing not have become deformed.
Compare the removed pipe with a new one.
CHECKING THE OIL PIPE
19. Fit the two wide-bore oil pipes to the pump. Check
that the O-ring to the suction line is in place. Fit
the short pipe between the valve housing and torque
converter housing.
OIL PIPE BETWEEN VALVE HOUSING AND OIL PUMP
20. Locate the valve housing and check that the pipes
engage the housing. Check that the manual gear
selector is connected.
472-11
Page 472
FITTING THE THROTTLE CABLE FITTING THE THROTTLE CABLE TO VALVE HOUSING
21. Secure the throttle valve wire and connect the inner
wire.
22. Tighten the three screws securing the valve housing.
FITTING VALVE HOUSING
472-12 SAAES Sept. 1973
Page 473
The following pipes are fitted on conjunction with step 23. Fit the remaining oil pipes in the following order:
16 (in the following order):
Return from the governor No. 1 Rear brake band (inner hole) No. 4
: UM. Rear brake band (outer hole) ee:
Main lubrication No. 2 Front brake band (applicati
Rear clutch No. 3 Np ade snare a
These are located under the rear bottom cover. ean a 2
: Front brake band (release
upper hole) fs
Front clutch and governor fd:
Front lubrication re)
Connect main lubrication
from No. 2 to No. 10
Connect rear clutchfromNo.3to “ 11
a governor return line
from No. 1 to No. 12
= = \, E
NS]
&
G
|
la
|
r
87654 3 2 1 s 3938
FITTING OIL PIPES
1. Return line from governor 7. Front brake band, releasing, upper hole
2. Main lubrication 8. Front clutch and governor
3. Rear clutch 9. Front lubrication
4. Rear brake band, inner hole 10. Main lubrication from 2
5. Rear brake band, outer hole 11. Rear clutch from 3
6. Front brake band, applica- 12. Return line governor from 1
tion lower hole
Jan. 1973 SAAB 472-13
Page 474
Pw
24. Fit the chain and sprockets and tighten.
TIGHTENING THE SPROCKET, THE WHEELS ARE LOCKED
WITH TOOL 879023
25. Mount the pinion shaft, crown wheel and differen- \
tial assembly with bearing housing. :
26. Check the backlash adjustment, and readjust if
necessary (see directions for assembly of pinion
bearing).
27. Fit bottom covers and cowlings.
Dismantling the front clutch
ae $2659
~
10, Wy 82
FRONT CLUTCH DISASSEMBLED
1. Lock ring 7. Lock ring
2. Input shaft 8. Return spring
3. Thrust washer 9. Piston sealing
4. Hub 10. Piston
5. Discs 11, Sealing ring
6. Spacer 12. Front clutch housing
472-14 SAAB Jan. 1973
Page 475
1 1. Remove plate. 7. Check all seals and clutch discs for damage and wear,
2. Remove lock ring from input shaft, saving the thrust replacing damaged parts. Do not forget the small O-ring
washer. on the cylinder hub. Check the small leaf valve on the
: 3. Lift out the forward clutch hub. back of the piston; spring movement should be 0,020—
4. Remove clutch discs. 0.039” (0.5—1.0 mm).
5. Remove lock ring for return spring and remove spring.
Assembling the front clutch
1. Before beginning assembly, lubricate all components
with automatic transmission oil.
2. Fit O-ring to cylinder hub.
3. Insert piston using sleeve 879010.
S$ 2660
REMOVING RETURN SPRING
6. Remove the piston with aid of compressed air.
; INSERTING PISTON IN FRONT CLUTCH
Tool 879010
eS
. Check that steel ring on piston is properly seated.
5. Fit return spring with convex part downward on pis-
ton.
6. Fit pressure plate with flat side upward, checking that
outer plates are flat; if not, they must be exchanged
for new ones.
7. Place hub, clutch discs and thrust washer in position.
8. Check that the bushing on the input shaft is intact.
At the same time, check that the seal rings on the
shaft rotate freely in their grooves. If the rings stick,
check that the housing is not damaged.
9. Lay the input shaft in the clutch disc housing and fit
the lock ring.
REMOVING FRONT CLUTCH PISTON WITH THE AID OF
COMPRESSED AIR
Dec. 1975 SAAB 472-15
Page 476
Dismantling the rear clutch
|s 2663
REAR CLUTCH DISMANTLED, EARLIER MODEL
$3901
REAR CLUTCH DISMANTLED, LATER MODEL
1. Rear clutch housing with forward sun gear
2. Sealing ring
3. Piston
4. Piston sealing
5. Spring
In the course of production of the 1972 model a new
rear clutch was introduced, fitted with three lock ring
grooves. The center groove is used for the standard disc
assembly. The new disc assembly has a thicker pressure
plate and one of the steel discs has been removed.
1. Pull out forward sun gear shaft.
NOTE: Thrust bearings on both sides of gear.
2. Remove lock ring securing clutch discs.
3. Compress return spring using tool 879008 in a press,
and remove the lock ring with aid of special pliers
879018.
REMOVING LOCK RING IN REAR CLUTCH,
Tools 879008 and 879018
4. Remove the piston with aid of compressed air.
472-16
6. Washer
7. Lock ring
8. Discs
9. Lock ring
REMOVING REAR CLUTCH PISTON
Assembling the rear clutch
1. Check the needle bearing and bushing in the hub. Make
sure there are no scratches on the drum. If scratches
are found, the drum must be exchanged. Small blue-
annealed areas can be accepted.
Check that the cylinder is free from scratches. Check
all seals and clutch discs; if in doubt, fit new parts. If
the piston has a leaf spring, check that the latter has a
movement of 0.020—0.039 in. (0.5—1.0 mm). Small
scratches on the piston can be smoothed off with a
fine cleaning cloth. Check the small O-ring on the
clutch housing hub.
Dec. 1975
Page 477
S
we
2. Install the piston with sleeve 879009 or 879069 de-
pending on piston design. The flat side shall be turned
downwards.
5.3006
INSTALLING PISTON IN REAR CLUTCH
Tool 879009 alt. 879069
3. Place the return spring on the piston.
4. Place the spring seat on the spring.
5. Compress the spring in a press with tool 879008 and
fit the lock ring. See page 472—16.
6. NOTE: The outer clutch discs are cambered, and the
cambers must face the same way.
Begin assembly of clutch discs with an outer disc,
finishing with a spacer disc and pressure plate.
7. Fit lock ring.
Dismantling the planet gear
1 2 3 4 5
PLANET GEAR WITH CENTRE SUPPORT AND FREE WHEEL
Centre support
Free wheel
Lock ring
}. Free wheel carrier
. Thrust washer
. Planet carrier
52006
PE aeNs
1. Pull out centre support from planet carrier and take out
free wheel.
2. Remove lock ring from planet carrier with a screw-
driver and pull out free wheel carrier.
Assembling the planet gear
1. Insert free wheel carrier and secure with lock ring.
2. Fit free wheel. NOTE: Flange on inner roller retainer
faces outwards.
3. Insert centre support in the planet carrier and check
that it can be rotated clockwise.
Dec, 1975
NOTE
There are two versions of the rear sun wheel and
the planet gear carrier and planet gear. The sun
wheel of one version and the planet gear carrier/
planet gear of the other version cannot be used to-
gether.
Identification grooves are used on the later version to
enable the two designs to be distinguished.
The rear sun wheel has a groove cut into the tops of
the cogs while the planet gear carrier has a groove
round its perimeter.
Exchanging the ring gear
It may be necessary to exchange the ring gear if its male
teeth have been damaged, e.g. by misuse of the parking
pawl.
NOTE: If the ring gear has jammed on the pinion splines,
the latter can be removed together with the pinion bearing
housing.
Remove lock ring and pull out shaft.
Reassemble in reverse order.
NOTE: Check that the seal rings rotate freely in their
grooves.
$2067
CHANGING RING GEAR
472-17
Page 478
. Remove shaft seals with a screwdriver.
. Tap the front race out gently with tool 879021.
9. Tap out the rear race with tool 879020 together with
drift 839044 up to and incl. gearbox No. 35 TB 2848.
As from gearbox No, 35 TB 2849, tool 879053 should
be used, together with drift 839044.
Dismantling the pinion bearings
on
When dismantling the pinion bearing the description
“dismantling the transmission” will be followed until the
pinion with its bearing housing has been removed. Then
the dismantling continued as follow below.
4. Undo the two screws securing the seal housing over
the pinion nut. Assembling the pinion bearing
2. Fit the pinion housing to fixture 879063 and its asso-
ciated retainer ring. Retainer ring 879066 should be 1. Fit the two shaft seals back-to-back in the housing
used for automatic transmissions of 1972 and earlier using tool 879016. Fit outer bearing rings.
models, while retainer ring 879065 should be used for 2. Press rear pinion bearing on to shaft.
1973 and later models.
3. Remove O-ring.
4. Clamp tool in a vice and unscrew pinion nut. oe
——————
uM
s
Ns
UNSCREWING THE PINION NUT
Tools 879026, 879063 and 879065 alt. 879066 W
$ 3206
5. Withdraw pinion from bearing housing. LOCATION OF PINION BEARING SHAFT SEALS
6. Press off the rear pinion bearing. Use the fixture and IN THE BEARING HOUSING
the retainer ring as a support (see point 2).
2. Press the rear pinion bearing onto the shaft. Fixture
879063 and press ring 879064 are used as a support.
PRESSING OFF THE REAR PINION BEARING
Tools 879063 and 879065 alt. 879066
PRESSING ON THE REAR PINION BEARING
Tools 879063 and 879064
472-18 SAAB Dec. 1975
Page 479
~~
3. Fit governor in housing with cover plate facing for-
ward.
4. Hold the shaft horizontal with the driver ball in posi-
tion and insert the shaft in the bearing housing so
that the ball engages the track in the governor.
. Shim between governor and front bearing.
6. Screw on nut and tighten to prescribed torque of
245—265 Nm (165—200 ft.lb., 25—27 kpm).
a
TIGHTENING THE PINION NUT
Tools 879026, 879063 and 879065 alt. 879066
7. Check the pre-load with a dynamometer 839013. Ad-
justment of the pre-load is carried out by placing
shims between the front bearing and the governor
housing.
Lubricate the bearing sparingly.
New bearings 27—46 N (6.1—10.3 Ib., 2.8—4.7 kp)
dynamometer reading which corresponds to a tor-
que of 1.8—3.0 Nm (15—25 in.lb., 0.18—0.30 kpm).
Old bearings that have done more than 1.200 miles
(2.000 km): 15—24 N (3.3—5.3 Ib., 1.5—2.4 kp)
dynamometer reading which corresponds to a tor-
que of 0.9—1.5 Nm (7.5—12.5 in.lb., 0.09—0.15
kpm).
PINION BEARING DISASSEMBLED
1. O-ring
2. Seal housing
3. Nut
4. Bearing
5. Shims
6. Governor
7. Shaft seals
8. Bearing housing
9. Pinion shaft
Dec. 1975 GAS
S 3207
CHECKING PRE-LOAD WITH SPRING BALANCE
Tools 839013, 879063 and 879065 alt. 879066
8. Fit seal housing and O-ring to bearing housing.
472-19
Page 480
Governor
At the moment there are two different types of governor.
Complete governors of both types are completely inter-
changeable.
S$ 2677
GOVERNOR DISASSEMBLED, EARLIER TYPE
1. Screws
Governor weight
Governor housing
Governor valve
Spring
Lock washer
Governor carrier
Washer
MPNAALYHON
®
$3407
GOVERNOR, LATER TYPE
. Lock washer for the governor weight
. Screws
. Governor weight
. Governor housing
. Governor valve
. Spring
Shaft
. Governor carrier
Washer
CONAGDAWN=
Dismantling the governor Assembling the governor
1. Take the governor off the carrier. Before reassembling, lubricate all parts with transmission
2. Undo the screws securing the cover washer on the oil.
governor housing. Reassemble in reverse order of dismantling.
3. Removing the lock washer and take out the governor
weight and valve.
472-20 SANE Nov. 1971