Page 491
Adjusting the contact for back-up lights and starter
Disconnect the cable. The wide terminals are for reversing
lights and the narrow ones for starter motor.
1. With the selector lever at D and the inhibitor switch
screwed out, connect a test lamp between the narrow
terminals (starter motor) via a battery. The lamp should
light up.
2. Screw in the inhibitor switch until the lamp goes out.
Mark the position on both the inhibitor switch and
the transmission. Move the test lamp to the wide
(reversing light) terminals and screw in the inhibitor
switch until the lamp lights up again. Count the num-
ber of turns between these two positions, and back off
to a point half-way between them.
3. Secure the lock nut with tool 879012 tightening to
the correct torque. NOTE: If the inhibitor switch is
locked too hard, it may be damaged.
S 2632
ADJUSTING THE CONTACT FOR BACK-UP LIGHTS AND
STARTER MOTOR
A. Lamp connected to the starter motor switch
8. Lamp connected to the back-up light switch
SAAB 472-31
Page 492
AOTDM AITAATS
BI esesanoD Gta] .A
Page 493
)
DIFFERENTIAL AND PINION/CROWN WHEEL GEAR
General
The crown wheel and pinion are a matched pair, so if one
is exchanged the other must be exchanged too, The parts
are tested together for noise and the optimum setting for
minimum noise output is measured. The key measure-
ments as far as the pinion and crown wheel are concerned
are firstly the distance from the end face of the pinion to
the center of the crown wheel, and secondly the backlash
between the teeth. These measurements and the mating
number are stamped into both parts at the time of noise
testing. When the pinion and crown wheel are installed,
these measurements must be accurately adjusted with
shims and a special measuring instrument. The pinion gear
shims are placed next to the bearing housing of the pinion
shaft bearings, and the crown wheel (differential) shims
are distributed between the two differential bearing seats.
Adjusting the position of the pinion gear
General
Data for adjustment of the distance from the pinion gear
to the center of the crown wheel are stamped into the
end face of the pinion (an example is illustrated below).
END FACE OF PINION
+3 = measurement for pinion setting
R913 = mating number, also stamped on crown wheel
0 = pinion not offset — shaft centerline intersects
crown wheel centerline (all pinions are marked
0 and this datum has no relevance to the adjust-
ment)
IMPORTANT
Before disassembling the transmission, always mea-
sure the positions of the pinion and crown wheel.
This provides a check on whether the setting may
have been wrong. If the pinion shaft and crown
wheel assembly has done less than 6,000 miles
(10,000 km), the setting can be adjusted, but after
longer mileage, when the gears will have worn them-
selves into a certain position, the parts should be
reassembled with the same settings as were mea-
sured prior to disassembly.
Before measuring
The following preparations must be made prior to mea-
suring the pinion gear setting:
With reference to manual transmissions up to and includ-
Dec. 1975
ing chassis No. 99722003498 and transmissions with col-
lapsible spacers starting from chassis No. 99722003499,
the following is applicable:
The pinion shaft bearings must be compressed until the
torque required to rotate the pinion shaft in the housing
is 1.8 + 0.5 Nm (16 + 4 in.Ib., 18 +5 kpem), correspond-
ing to a dynamometer reading of 31.4—56.0 N (7—12.5 Ib.,
3.2—5.7 kp). These figures apply to new, lightly oiled bear-
ings that have done more than 1.200 miles (2.000 km)
the torque should be 0.9 + 0.5 Nm (8 + 4 in.Ib., 9+ 5 kpem),
corresponding to a dynamometer reading of 10—34 N (2.2—
7.7 |b., 1.0—3.5 kp).
In the case of manual transmissions as from chassis No.
99722003499 with solid spacers the following is applica-
ble:
The pinion shaft nut must be tightened to 150—200 Nm
(110-150 ft.Ib., 15—20 kpm). The torque required to ro-
tate the pinion shaft in the housing must be 2.5 + 0.5 Nm
(22 + 4 in.lb., 25 +5 kpcm), corresponding to a dynamo-
meter reading of 48—71 N (10.4—15.4 Ib., 4.7—7.0 kp).
These figures apply to new, lightly oiled bearings. For
bearings that have done more then 1.200 miles (2.000
km) the torque should be 1.3 + 0.5 Nm (11.6 + 4.4 in.|b.,
13 + 5 kpem), corresponding to a dynamometer reading
of 19—43 N (4.2—9.5 Ib., 1.9—4.3 kp).
In the case of automatic transmissions the following is
applicable:
The pinion shaft nut must be tightened to 245-265 Nm
(180—200 ft.Ib., 25-27 kpm). The torque required to
rotate the pinion shaft in the housing must be 1.8—3.0
Nm (16-26 in.Ib., 18—30 kpcm), corresponding to a dy-
namometer reading of 27—46 N (5.9—10.1 Ib., 2.7—4.6
kp). These figures refer to new, lightly oiled bearings.
For bearings that have done more than 1.200 miles
(2.000 km) the torque should be 0.9—1.5 Nm (8—13
in.lb., 9-15 kpem), corresponding to a dynamometer
reading of 15—24 N (3.3—5.3 Ib., 1.5—2.4 kp).
The differential unit must be removed to permit installa-
tion of the measuring instrument (tool 839015), which
consists of a measuring jig with attached indicator dial
784062. A ground gauge block is provided for calibration
of the dial; the block is laid against the calibration stops
of the instrument, and the distance between these stops
and the centerline of the tool is exactly 2.362” (60.000
mm), equal to the distance from the end face of the pin-
ion shaft to the center of the crown wheel (see illustra-
tion). The procedure for measuring the pinion gear posi-
tion is as follows:
CALIBRATING THE INSTRUMENT DIAL
Measuring instrument 839015 and instrument dial 784062
473-1
Page 494
Measuring
1. Check that the pointers of the instrument are zeroed
when the measuring point touches the gauge block (see
illustration).
2. Place the instrument in the differential housing with
the point applied to the flat end of the pinion gear and 3
take a reading (see illustration).
ZL VA 2
BS N \ S
ny
1 S 1845 »
ADJUSTING THE PINION GEAR, MANUAL TRANSMISSION
1. Shim
2. Roller bearing
3. Bearing housing
4. Pinion y
MEASURING TOOL LOCATED IN DIFFERENTIAL BEARING SHIM TABLE, MANUAL TRANSMISSION
OPENINGS, MANUAL TRANSMISSION
3. When the pinion gear is correctly positioned, the dial ' Shims
should show the number of hundredths of a millimeter Eocation Thickness mm_ Spare part No.
(+ or —) stamped into the pinion with a permitted
tolerance of + 0.05 mm. Pinion shaft between 0.10 834175
‘ bearing housing and 0.15 834176
transmission case 0.30 834177
0.50 834472
MEASURING TOOL LOCATED IN AUTOMATIC TRANS- ADJUSTING THE PINION GEAR, AUTOMATIC TRANS-
MISSION MISSION
1. Shims
A 6 2. Roller bearing
Shimming
3. Bearing housing
4. Pinion gear
If the measured reading is outside the permitted tolerance,
the pinion shaft must be adjusted. This is done with shims
placed between the pinion shaft bearing housing and the
transmission case (see illustration).
473-2 SAAB Nov. 1971
Page 495
SHIM TABLE, AUTOMATIC TRANSMISSION
7 Shims
ition
cocats Thickness mm_ Spare part No.
Pinion shaft between 0.10 870748
bearing housing and 0.15 870749
transmission case 0.30 870750
Procedure for shimming is as follows:
1. Undo the four screws from the pinion shaft bearing
housing and tap the pinion shaft gently out of the
transmission case.
2. Change the shimming according to the following
rules: $
a) If the dial reading is higher than the correct value,
increase the shim combination.
b) If the dial reading is lower than the correct value,
reduce the shim combination.
NOTE! + reads clockwise and — reads counter-
clockwise on the dial.
Reduce or increase the shim combination by the dif-
ference between the measured and correct values.
$948
If the pinion is stamped —7, the pointers should indicate
—0.07 mm. A deviation of +0.05 mm from this reading
is permitted.
Checking the measuring jig
The measuring jig is a precision-made tool. It should be
handled with care to avoid knocks and deformation. If
there is reason to suspect that the jig may have been dam-
aged in such a way that it gives wrong readings, it can be
measured as a check. The dimension indicated in the illus-
tration on the right should be measured for this purpose.
Jan. 1971 Se,
3. Having selected the correct combination of shims,
place them in the transmission case with aid of the
locating pins 839016. Mount the pinion shaft to
the transmission case using sleeve 839014 and ar-
bor 839011. Remove the locating pins and tighten
the screws to the prescribed torque and lock them
with Loc-tite.
Rechecking
After shimming, replace the measuring jig in the differ-
ential housing and check that the dial now gives the correct
reading to within +0.05 mm. If it does not, the shimming
procedure must be gone through again.
If the pinion is stamped +3, the pointers should indicate
+0.03 mm. A deviation of +0.05 mm from this reading
is permitted.
CHECKING THE JIG
473-3
Page 496
Adjusting crown wheel backlash, manual and automatic
transmission
Certain data for adjustment of crown wheel backlash are
stamped into the crown wheel as illustrated below.
R 913 38 9nens
$2467
CROWN WHEEL MARKINGS
38 = No. of teeth on crown wheel
9 = No. of teeth on pinion
-15 = backlash 0.15 mm
R913 = mating number, also stamped on pinion
The backlash should be checked at four points round the
circumference of the crown wheel and must not deviate
by more than +0.05 mm from the stated measurement.
Crown wheel backlash is adjusted with shims. Up to four
shims may be used in suitable combinations.
TABLE SHIMS
Location pais
Thickness mm_ Spare part No.
Between differen- 0.10 834160
tial bearing seat and 0.15 834161
transmission case 0.30 834162
0.50 834163
473-4 SAAB
Jan. 1971
Page 497
Measuring and shimming automatic transmission, and
manual transmission as from transmission serial No. 4007
A new bearing seat has been introduced for the differen-
tial in manual transmissions with serial numbers 4007 and
higher. This means that the journal bearings must be ad-
justed with shims.
Adjustment of differential bearings
NOTE
Adjustment must be done before the pinion shaft is
mounted.
1. Place the differential assembly complete with crown
wheel in the transmission case.
2. Mount the left bearing seat (the one with the speedo-
meter drive) without shims and tighten the screws to
the prescribed torque of 20—25 Nm (14-18 ft.lb.,
2.0—2.5 kpm).
3. Oil the differential bearings and mount the right bear-
ing seat, tightening the screws in two or three stages to
2.2 Nm (20 in.lb., about 22 kpcm). Rotate the diffe-
rential while tightening the screws.
TIGHTENING THE RIGHT BEARING SEAT
4. Measure the gap between the transmission case and
bearing seat with a feeler gauge at two points opposite
each other and take an average of the two measure-
ments. Then select shims corresponding to this result
plus an increment of 0.20 mm to obtain the correct
bearing compression.
MEASURING BEARING SEAT GAP
NOTE
The method described above applies to both new
and old bearings.
The compression obtained in this way corresponds to a
friction torque of 1.8 + 0.5 Nm (16+ 4.5 in.Ib., 18 +5
kpcm) on the differential. If a line is wound round the
widest part of the differential and a dynamometer attached,
the following readings should be obtained:
New, lightly oiled bearings 31-56 N (7—12.5 Ib., 3.2-5.7 kp)
Bearings that have done
more than 1,200 miles
(2,000 km) 10—34 N (2.5—7.7 Ib., 1.0—3.5 kp).
Shims of four different thicknesses can be suitably com-
bined. The available thicknesses are shown in the table
below
TABLE SHIMS, MANUAL AND AUTOMATIC TRANSMISSION
3 Shims
Eocation Thickness mm Spare part No.
Between differen- 0.10 834160
tial bearing seat and 0.15 834161
transmission case 0.30 834162
050 834163
NOTE
The resulting set of shims should then be distributed
between the right and left sides to give the correct
gear backlash.
Nov. 1971 SAAB 473-5
Page 498
Adjusting crown wheel gear backlash
1. Place the differential assembly complete with crown
wheel in the transmission case.
2. Mount the left bearing seat (the one with the speedo-
meter drive) without shims and the right bearing seat
with the selected set of shims, tightening the screws
to the prescribed torque of 20—25 Nm (14—18 ft.lb.,
2.0—2.5 kpm).
3. Fit a special fixture in one of the holes for the diffe-
rential housing cover and install instrument dial
784062. Use fixture 839028 for manual transmission
and fixture 879006 for automatic transmission.
MEASURING GEAR BACKLASH,MANUAL TRANSMISSION
Tools 784062 and 839028 .
MEASURING GEAR BACKLASH, AUTOMATIC TRANS-
MISSION
Tools 784062 and 879006
4. Calculate the difference between the measured back-
lash and the desired gear backlash, and then move
shims of suitable thickness over to the left bearing
seat. Measure again afterwards as a check.
473-6
NOTE
The preselected set of shims must be used for ad-
justing the backlash. The total thickness of the set
must not be altered. !
Differential, manual and automatic transmission
Removing
To exchange parts inside the differential assembly it is
only necessary to unscrew the two long crown wheel
screws that locate the differential gear shaft, see illustra-
tion. The shaft and gears can then be taken out without
removing the differential assembly.
DIFFERENTIAL ASSEMBLY
1. Remove the universal joints and the rear cover of the
differential housing.
2. Take off the two differential bearing seats and lift out
the differential assembly, saving the spacers and shims.
3. If necessary, press the outer bearing rings out of the
bearing seats using washer 839029 and drift 839018.
Remove the speedometer drive and press both journal
bearings off the differential housing using tools
899518, 899525 and 899517.
SAAB Dec. 1975
Page 499
4. Mount the crown wheel and tighten the screws to
25 Nm (18 ft.Ib., 2.5 kpm) torque. Note that the two
longer screws also serve to locate the differential shaft
axially. (Valid for gear boxes with serial numbers below
500.000.)
5. Transmissions with serial numbers below 500.000: lock
the crown wheel screws with lock washers.
Transmission with serial numbers over 500.000: use
Loctite stud lock” to lock the crown wheel screws.
Press on the journal bearings and the speedometer
drive, if these have been previously removed, using
tool 879048.
oo $1881
REMOVING DIFFERENTIAL JOURNAL BEARINGS
Puller 899518, 899525, wheel nuts 890914
4. Remove the crown wheel screws and take off the crown
iy wheel.
5. Push out the differential gear shaft.
6. Remove the gears from the differential casing and take
the springs out of the gears. As from gear box No.
500.001 also the wear washers are to be removed. PRESSING ON THE DIFFERENTIAL JOURNAL BEARINGS
6. Locate the differential assembly in the transmission
Assembling case. If any part affecting the overall width of the dif-
ferential assembly — e.g. the bearings — has been ex-
IMPORTANT changed, the crown wheel backlash must be adjusted.
\f the crown wheel is exchanged, the pinion gear This is done by alteration of the combination of shims.
must be exchanged with it, as these two parts are See section ‘Adjusting crown wheel gear backlash’’.
individually matched. 7. Press the outer bearing rings into the bearing seats
using tool 839031 and change the shaft seals if neces-
1. Exchange worn or damaged parts. sary. Use tool 839032. Mount the bearing seats on the
2. Mount the springs in the two bigger gears. transmission case and tighten the screws to the pre-
3. Locate the gears and wear washers if any in the diffe- scribed torque.
v ) rential casing and slide in the differential shaft. As
4 from gear box No. 500.001: Fit the lock rings on the
shaft.
SEATING THE OUTER BEARING RINGS
= Tools 839031 and 839032
WEAR WASHERS 8. Mount the rear cover of the differential housing and
both universal joints.
Dec. 1975 SAAB 473-7
Page 500
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