Page 551
i a ge i a a
Installation
1. Replace the direction indicator switch actuator if it has
been taken out. Make sure that its center line coincides
with the center line of the switch housing when the
front wheels are straight ahead. Install the plastic
sleeve on the driver.
CAUTION
The actuator is so designed that it is located on the
steering column with a certain grip. On no account
must it be welded to the column.
NOTE
As from chassis No, 99.063.198, the spacer sleeve
should be mounted on the actuator.
2. Fit the steering wheel on to the steering column. The
front wheels should be aligned straight ahead and the
steering wheel mounted with the spokes forming a
symmetrical inverted vee.
3. Mount the bottom cover of the steering wheel bearing,
checking that the friction washer is properly seated.
As from model 1970: replace the horn contact finger.
4. Fit the steering wheel safety pad.
Model 1969: replace the plug.
WARNING
The collapsible steering wheel shaft introduced as
from chassis No. 99.008.870 must be handled with
care. It must not be subjected to impacts, jolts or
other rough treatment liable to alter the adjusted
length of the telescope joint or impair its shock-
absorbing effect.
When installing the steering wheel shaft, take special
care to ensure that the splined lower end is pushed
into the intermediate shaft until the clamping screw
comes opposite the groove in the shaft. The inter-
mediate shaft should normally slide freely on the
shaft. If the splines stick, do not on any account
knock on the top end of the steering wheel shaft.
This also applies to removing and fitting the steering
wheel. The wheel must not be knocked off or on.
When the car is on a hoist, do not seize a front wheel
and twist it by main force to full steering-wheel
lock. There is a very serious risk of damaging the
steering mechanism if this is done, as the rack-and-
pinion gear will cause the steering wheel to spin at
high speed, imposing a severe torsional strain on the
steering column when the rotation is arrested by
the stop in the steering gear.
Dec, 1975
Removing the steering column tube
1. Undo the locking screw at the joint.
2. Undo the two lower retaining screws at the pedal
bracket and the two upper retaining screws. (Steering
column tube- instrument panel.)
3. Detach the quick-release wiring connection and lift
out the steering column assembly.
Mount in the reverse order.
Disassembling the steering column
1, Undo the three retaining screws and remove the plastic
cover under the steering wheel.
2. Pull the steering wheel shaft out of the tube.
3. Remove the two rubber bushings with associated
steering wheel shaft bushings and washers.
Reassemble in the reverse order.
Replacement of sealing bellows on intermediate shaft
Removing
1. Remove the cover under the instrument panel. (Valid
for cars as from model 1971.)
2. Undo the screw, which holds the steering column to
the intermediate shaft.
3. Undo the four screws, which fasten the steering column
tube to the body.
4. Withdraw the steering column from the intermediate
shaft.
5. Cut off the old sealing bellows.
INSTALLATION OF SEALING BELLOWS, INTERMEDIATE
SHAFT
Installation
1. Lubricate tool 899581 with vaseline or soapy water.
Place the tool against the intermediate shaft. Ease the
new sealing bellows over the tool and the joint. Check
that the bellows are undamaged.
2. Refit the steering column into the intermediate shaft.
Make sure that it is pushed in so that the screw is
located directly opposite the groove. Tighten the screw.
3. Fasten the steering column to the body.
4. Check the position of the steering wheel and adjust if
necessary.
. Fit the bellows in the dash panel.
6. Refit the cover under the instrument panel. (Valid for
cars as from model 1971.)
a
641-3
Page 552
STEERING GEAR
General
The steering gear is precision adjusted before delivery
and should not be disassembled unless absolutely neces-
sary. As from chassis‘No. 99.022.279 up to 4nd incl.
model 1972 the steering gear is permanently grease lubri-
cated. Earlier steering gears have lubrication nipple. As
from the 1973 modef the steering gear is oil lubricated
but in other respects the same’as the permanently lubri-
cated type.
Disassembly and reassembly of the different steering
gears are to be found in two separate sections 642—3
and 642—6 respectively.
Turn the steering wheel to full left lock before greasing.
Use Saab Special chassis grease. Lubricate generously to
ensure smooth action but not so much that the bellows
are distended with grease.
Check occasionally to see that the oil-lubricated steering
gear is not leaking. Check the oil level every 30,000 miles
(50,000 km). See page 120—4.
Regarding the power steering gear, see section 644.
If the steering gear is noisy, it must be adjusted (see section
“Adjustment of steering gear’). The illustration shows
the steering gear of a left-hand-drive car. As the steering
gear of the right-hand-drive model is essentially similar,
the instructions given here apply to both types.
STEERING GEAR UP TO AND INCL. CHASSIS NO. 99.022.278 27
1. Steering gear 10. Spring 21. Clamp $2432
housing assembly 11. Fitting 22. Rubber bellows
2. Rack 12. Lock nut 23. Washer
3. Bushing 13. Grease nipple 24. Clamp
4. Pinion 14. End piece 25. Nut
5. Ball bearing 15. Spring 26. Tie rod end assembly
6.” Lock ring 16. Shim 27. Nut
7. Sealing ring 17. Inner bearing cup 28. Rubber bushing
8. Fitting 18. Lock washer 29. Bushing
9. Plunger 19. Tie rod
20. Outer bearing cup
642-1 SAAB Dec. 1975
Page 553
ga
$2433
STEERING GEAR, AS FROM CHASSIS NO. 99.022.279
1. Steering gear housing 12.
assembly 13.
2. Rack 14,
3. Ball bearing 15.
4. Pinion 16,
5. Ball bearing ek
6. Shim 18.
7. Gasket 19.
8. Cap 20.
9. Washer 21.
10. Screw 22.
11. Seal ring 23.
Some previously grease-lubricated steering gears have been
modified for oi! lubrication and fitted with a screw clamp
at the attachment of the rubber bellows to the tie rod.
These steering gears should also be checked to see that oil
is not leaking out.
Removing the steering gear (left-hand-drive car)
1. Jack up the front of the car.
2. Remove the fromt wheels.
3. Disconnect the ftie-rod ends from the steering arms
using tool 899540. Undo both retaining caps.
Clip 24. Ring
Rubber bellows 25. Tie-rod end
Clip 26. Lock nut
Plunger 27. Tie rod
Spring 28. Outer bearing cup
Shim 29. Lock nut
Gasket 30. Inner bearing cup
Cap 31. Spring
Washer 32. Bushing
Screw 33. Cotter pin
Nut 34, Rubber bushing
Rubber bellows
DISCONNECTING THE STEERING ARM
Tool 899540
Dec. 1975 SAAB
642-2
Page 554
4. Turn back the floor carpet round the intermediate shaft
and pull up the rubber bellows to expose the lower joint.
5. Undo the clamping screw on the steering gear pinion.
Separate the upper joint and remove the four retaining
screws that hold the steering column tube. Pull up the
steering column a little so that the intermediate shaft
can be removed. Pull out the steering gear assembly
from the left. (From the right on R.H.D. cars.)
$2078
REMOVAL OF STEERING GEAR ASSEMBLY
Installing the steering gear assembly
1. Insert the steering gear assembly through the opening
in the left wheel housing. (Right wheel housing on
R.H.D. cars.) When a new steering gear is installed the
paper cylinders on the bellows should be left until the
gear is in place.
2. Mount the retaining caps and tighten the four nuts.
3. Connect the tie rods to the steering arms and tighten
the self-locking nuts.
4. Mount the intermediate shaft and locate the steering
column tube. Tighten the locking and retaining
screws,
5. Locate the rubber bellows over the lower joint and lay
the carpet.
6. Mount the wheels and lower the front of the car.
WARNING
The collapsible steering wheel shaft introduced as
from chassis No. 99.008.870 must be handled with
care. It must not be subjected to impacts, jolts or
other rough treatment liable to alter the adjusted
length cf the telescope joint or impair its shock-
absorbing effect.
When installing the steering wheel shaft, take special
care to ensure that the splined lower end is pushed
into the intermediate shaft until the clamping screw
comes opposite the groove in the shaft. The inter-
mediate shaft should normally slide freely on the
shaft. If the splines stick, do not on any account
knock on the top end of the steering wheel shaft.
This also applies to removing and fitting the steering
wheel. The wheel must not be knocked off or on.
When the car is on a hoist, do not seize a front
wheel and twist it by main force to full steering-
wheel lock. There is a very serious risk of damaging
the steering mechanism if this is done, as the rack-
and-pinion gear will cause the steering wheel to spin
at high speed, imposing a severe torsional strain on
the steering column when the rotation is arrested
by the stop in the steering gear.
Steering gear up to and incl. chassis No. 99.022.278
Disassembling the steering gear
1. Undo the lock nuts and unscrew the tie-rod end
assemblies.
. Remove the clamps and the rubber bellows.
. Prize up the lock washers.
4. Disassembly the two tie-rod ball joints by unscrewing
the outer bearing cup with a ring spanner. Put the
outer cups, lock washers, inner cups, shims and spring,
carefully aside. Grip the rack in a vise between two
wooden blocks and unscrew the end pieces.
WN
tice fv o> ©?) SB pee
1 2 3 45 67
BALL JOINT, DISASSEMBLED
1. End piece
2. Spring
3. Shim
4. Inner bearing cup
5, Lock washer
6. Tie rod
7. Outer bearing cup
Jan. 1973
Page 555
i
. Undo the lock nut of the rack adjustment and remove
the fitting, spring and plunger.
. Remove the pinion after unscrewing the fitting;
extract the pinion using tapping hammer 839027 and
puller 899528.
2080
REMOVING THE PINION
Tools 839027 and 899528
. If the bearing is damaged, it can be freed with the help
of a piece of pipe of matching diameter cr a puller
after the lock ring has been removed.
. Pull the rack out of the steering gear housing, saving
the plastic plug under the rubber bushing.
. If the bushing at the right-hand end of the steering
gear needs exchanging, use tool 899537 to expel it.
Assembling the steering gear
Scrupulous cleanliness is essential during the assembling
Operation. Lubricate gear teeth, bearing points and other
sliding contact surfaces with Saab Special chassis grease.
ak
Fit any bushings that have been removed into the
steering gear housing. The hole in the large bushing
must be in line with the hole in the housing.
2. Insert the rfck into the housing, locate the pinion
with bearing and lock ring, and tighten the fitting
against the outer ring of the ball bearing. Insert the
plastic plug and the rubber bushing.
Dec. 1975
Mount the plunger, spring, fitting and lock nut for
the radial adjustment of the rack.
Fit the bellows clamp at the right-hand end of the
steering gear. Screw the endpieces on to the rack
and lock them (see illustration). Fit the lock wash-
ers, springs, shims and inner bearing cups.
$2081
LOCKING THE END PIECE WITH A PUNCH MARK
vl
Mount the outer bearing cup on the tie rod and
tighten it firmly against the nut.
Check that the ball joints are properly shimmed.
If not, unscrew the outer cup and change the shim
combination (see under Adjustment).
After adjusting the ball joint, bend the lock washer
Over the outer bearing cup and endpiece.
Adjust the radial play of the rack (see under Ad-
justment).
Fit the rubber bellows and screw the clamps to the
steering gear and tie rod respectively, but not too
tight — it must be possible to twist the tie rod in
the bellows.
NOTE
Use band type clamps. Wire clamps may not be
used.
Tis
Screw on the lock nuts and mount the tie-rod and
assemblies on the tie rods.
Grease the steering gear; check by feeling the rubber
bellows that the grease is distributed along the full
length of the steering gear assembly.
642-4
Page 556
Adjustment of steering gear
The adjustments that may be required are as follows:
1. Adjustment of rack radial play.
2. Adjustment of tie-rod inner bail joints.
The steering gear assembly must be removed from the
car for adjustment of the inner ball joints, but the radial
play of the rack can conveniently be adjusted with the
steering gear in place, unless it has had to be removed for
some other reason.
The inner ball joints will seldom need adjustment, as there
is very little wear on them, besides which they are self-
adjusting to some extent.
Adjusting the pinion play
If noise or knocking is noticed in the steering mechanism,
the pinion ought to be checked for possible radial or axial
backlash.
Backlash may occur if some part has been changed or as a
result of wear. Normal wear is very low, so adjustment on
this account is seldom called for provided that the parts
have been kept well greased.
Axial and radial backlash in the pinion (steering column
shaft) can only'be corrected by a change of bushing and/
or ball bearing, for which purpose the steering gear assem-
bly must be removed'from the car. On assembly, fitting
890303 must be tightened so that its lower end butts
firmly against the outer ring of the ball bearing.
Adjusting radial backlash in the rack
The radial backlash of the rack is adjusted by a threaded
fitting (adjusting screw) on the underside of the steering
gear. This adjustment can be made with the steering gear
in place in the car.
1. Unscrew the lock nut.
2. Screw the fitting right home.
3. Slacken the fitting about 1/8—1/4 turn and tighten
the lock nut.
4. If necessary, readjust and then check that the rack
does not stick in any position from lock to lock.
Adjusting the tie-rod inner ball joints
The tie rods (see illustration) are exactly the same on both
sides. The inner end of each rod where it connects to the
steering rack is spherical, while the outer end is threaded
to engage the female thread of the outer ball joint assembly.
1. To adjust the inner ball joint, the steering gear assembly
must first be removed from the car.
2. Undo the clamps and take off the rubber bellows.
3. Pull the rack as far as it will come to one side. Straighten
out the lock washer and then separate the outer bearing
cup from the nut (see illustration).
|
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7 $209
BALL JOINT, DISASSEMBLED
. End piece
. Spring
Shim
Inner bearing cup
Lock washer
Tie rod
. Outer bearing cup
MONSYNS
4. Fit a new lock washer on the inner nut. Place a suit-
able combination of shims between the inner bearing
cup and the nut.
5. Slip the outer bearing cup over the tie rod and screw
the cup tight to the rack endpiece.
6. Check that the shimming is correct. The ball joint
should have no play whatsoever and should remain
in any position to which it is moved without the tie
rod sagging under its own weight; the joint must not
however be so tight that it sticks in any position. It
should be possible to move the tie rod to its full limit
of travel in any direction by applying a force of 29 N
(6,5 Ib, 3 kp) to the end of the rod.
Dec. 1975
Page 557
7. If the shimming is not correct, the outer bearing cup 4. Remove the outer bearing cups and lock nuts using
must be unscrewed again and the number of shims tool 839019 and polygrip pliers (see illustration).
increased or reduced. Then lock the lock washer.
8. Repeat the adjustment in the same manner for the
other tie rod.
9. Inspect the rubber bellows and fit new ones if neces-
sary. Mount the steering gear assembly in the car.
NOTE
While the steering gear is out of the car, check the
radial backlash of the rack and pinion.
~ Steering gear, as from chassis No. 99.022.279
Disassembling the steering gear
1. Back off the lock nuts and unscrew the tie-rod ends.
2. Undo the clips and remove the rubber bellows.
3. Drill out the cotter pins from the inner ball joints using
a 4 mm bit. The pins are 3/8” (9.4 mm) long (see illus-
REMOVING OUTER BEARING CUP AND LOCK NUT
Tool 839019 and polygrip pliers
tration).
5. Undo the rack adjustment screws and remove the cap
CAUTION with gasket, shims, spring and plunger.
Boinotdrillitoo deep; 6. Undo the pinion screws and remove the pinion with
cap, gasket, shims and upper bearing.
7. Pull the rack out of the steering gear housing.
8. Remove the lower pinion bearing by tapping the housing
on a porous surface. The bushing in the end of the
steering gear housing should not normally be changed,
as it must be precision reamed in order to function
properly.
Assembling the steering gear
Scrupulous cleanliness is essential during the assembling
operation. Make sure that the steering gear is well lubri-
cated with Saab Special chassis grease, as it cannot be
lubricated after it has been assembled (valid up to and
incl. the 1972 model).
1. Seat the lower pinion bearing.
CAUTION
Make sure that both pinion bearings are the right
way up. The extended parts of the inner bearing
tracks should face each other.
DRILLING OUT THE COTTER PIN
2. Assemble the inner ball joint on the pinion end of
the rack as follows:
Thread the lock nut on to the rack. Fit the outer
bearing cup on the rack and fill it with Saab Special
chassis grease (valid up to and incl. the 1972 model).
Insert the spring and inner bearing cup and tighten
the bearing cup.
Dec. 1975 SAAB 642-6
Page 558
3. Tighten the bearing cup so that there is no looseness
in the ball joint, but not so tight that the ball sticks
in any position.
If the rack with tie rod mounted is held horizontal,
the ball joint should be so tight that the tie rod with
tie-rod end fitted can be placed in any position
without bending down under its own weight.
CAUTION
The tie rod must not on any account stick in any
position. It must be possible to move the rod to its
full limit of travel in any direction by light hand
pressure.
4. Tighten the lock nut against the bearing cup using
tool 839019 and polygrip pliers, and check again
that the ball joint is neither too tight nor too slack.
Drill a new hole for the cotter pin 4 mm in dia-
meter and 3/8" (9.4 mm) deep and insert a new
cotter pin, securing it by four center punch blows
at the edge of the hole. Be extremely careful that
no drill shavings get into the steering gear.
5. Insert the rack in the housing. Then fit the pinion
and upper bearing. Adjust the pinion with shims so
that there is no axial play when the gasket and cap
are mounted. Shims are available in thicknesses of
0.005". 0.0075", 0.010" and 0.090” (0.13, 0.19,
0.25 and 2.33 mm).
6. Adjust the radial play of the rack as follows:
a. Fit the plunger without the spring and screw on
the cap without the gasket by hand until it butts
against the plunger (see illustration). If a wrench
is used, the cap will be deformed.
It is also possible to adjust the radial play of the
rack,when the steering gear is in place in the car.
2 1
VIE
N
S 2436
CAP AND PLUNGER FITTED FOR MEASUREMENT OF PLAY
1. Clearance to be measured with feeler gauge
2. Cap
3. Plunger
ou2—7 SAAB
b. Measure the clearance between the cap and hous-
ing with a feeler gauge (see illustration).
$2507
MEASURING CLEARANCE BETWEEN CAP AND HOUSING
c. Add 0.002” — 0.006’ (0.05 — 0.15 mm) to the
measured clearance to allow for the play to be left
between the plunger and cap after assembly. If for
example the feeler gauge measurement is 0.022”
(0.55 mm), the total thickness of gasket and shims
should be 0.024’ — 0.028’ (0.60—0.70 mm).
Measure the thickness of the gasket and shims with
a micrometer (see illustration).
Shims are available in thicknesses of 0.005”.
0.0075", 0.010’, 0.015” and 0.020” (0.13, 0.19,
0.25, 0.38 and 0.51 mm).
MEASURING GASKET AND SHIMS
Jan. 1971
_
Page 559
7. Fit the plunger, spring, shims, gasket and cap.
8. Check that the rack does not stick in any position
by rotating the pinion with tool 899528 (see illus-
tration).
$2409
CHECKING THAT THE RACK DOES NOT STICK
Tool 899528
9. Ina correct adjusted ‘Steering gear, the torque should
be 1.1—2.1 Nm (0.83—1.5 ft.lb., 11.5—20.7 kpem).
This is checked with the aid of dynamometer 839013,
brake spring tool 899560 and tool 899528. Connect
the brake spring tool according to figure. A lever
arm of about 6.03 (16 cm) is then obtained which
corresponds 7—14 N (5.5—11 ft.lb., 0.7—1.4 kp) on
the dynamometer.
83177
CHECKING THE STEERING GEAR TORQUE
Tools 839013, 899528 and 899560
10.
v1:
12.
Dec. 1975 SAAB
Assemble the other ball joint and adjust in the same
manner as before.
Fit the rubber bellows and secure the clips round
the steering gear. As from model 1973, the contact
area between the rubber bellows and tie rod is lu-
bricated with silicone grease. Fit all clamps except
One of the outboard ones. Stand the steering gear
assembly on end and pour in 5 fl.oz., 0.15 dm3
(1.5 dl) of EP 90 oil between the rubber bellows
and tie rod, using an oil can. Fit the remaining
clamp and make sure that the threads of the out-
board clamping screws are protected by rubber
caps.
Screw on the lock nuts and mount the tie rod end
assemblies on the tie rods.
642-8
Page 560
Steering gear, as from model 1973
The steering gear ratio has been modified commencing
with the 1973 model. The number of turns of the steer-
ing wheel from lock to lock has been increased from 3.5
to 3.7. This has been achieved by lengthening the steer-
ing arms and the rack.
Two alternative versions are fitted to the earlier 1973
models. The first version is fitted to vehicles up to chassis
number 99732005773 and also in a limited number of
cars with higher chassis numbers. The later version used
a0.4” (10 mm) shorter rack, compensated for by a 0,2”
(5 mm) increase in the length of both tie rods. In addi-
tion, the locking nut for the inner ball joint is 0.5” (13
mm) thick on the first version as compared with 0.3”
(8 mm) on the later type.
WARNING
The short tie rods must not in any circumstances be
used in conjunction with the new short rack. This is
because the screw threads at the ends of the tie rods
would then be too short. Only the longer type of tie
rods is available as a spare part. (See the attached
table.)
Exchanging Fit
Note
Complete steering gear
Steering gear 892009
(RHD 892010)
Only the later version is available as a spare part.
Rack
Rack 892217
(RHD 892218)
Only 892217 (RHD 892218) is available as a spare part.
Rack 892217 (RHD 892218) must only be fitted in conjunc-
tion with the rods type 892216.
Tie rod
Tie rod 892216
Only 892216 is available as a spare part.
When tie rod type 892216 is fitted to the earlier type of steer-
ing gear, there is a possibility that the tie rod screw thread may
butt against the tie rod end, thus restricting adjustment possi-
bilities. If this happens, the threaded end should be ground off
by max. 0.2" (5 mm).
In order to make it possible to distinguish different types of tie
rod, the new long version (892216) is provided with a machined
track. See diagram.
892015 (short)
Track
892216 (long)
Jan. 1973
a - «CE