Page 591
Changing the wheel bolts
Removal
1. Remove the brake disc, see group 5. On the front
wheels, also remove the handbrake shoes.
2. Press out the wheel bolts, using pressing tool 899592
with the removal sleeve on the inside of the hub.
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REMOVING A WHEEL BOLT
Pressing tool 899592 with removal sleeve
Installing
1. Press in the new bolt, using pressing too! 899592.
2. Mount the handbrake shoes (front wheels) and the
brake disc. Adjust the handbrake shoes (front wheels).
INSTALLING A WHEEL BOLT
Pressing tool 899592
Dec. 1975 Saar 774-8
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Page 592
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Page 593
2 AB .-
Jan. 1972
CONTENTS
800 General
810 Body assembly
820 Hood, front, fenders
830 Doors and trunk lid
843 Windows
851 Upholstery and interior fittings
852 Seats and carpeting
853 Interior minesae
854 Heating and ventilation system
860 Bumpers
890 Body finishing
SAAS
Page 594
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Page 595
GENERAL
The car has an all-welded cantilever steel unit body, The
doors, engine hood and trunk lid are removable, while
the front and rear fenders are welded on to form integral
load-carrying parts of the body.
The body is constructed of a relatively small number of
sections of pressed steel sheeting. These are joined togeth-
er mainly by spot-welded overlapped joints. Body rigidity
is achieved by longitudinal and transverse floor beams,
heavy-gauge windshield pillars and profiled stiffeners round
the roof. Moulded stiffening frames reinforce the windshield
and back window. As from the 1973 model all doors are’
equipped with a reinforcement beam that gives improved
protection if the car is involved in a side collision. Rein-
forcing pieces and brackets are welded to the engine and
chassis unit mountings to take up prevailing forces.
The floor comprises front and center sections, cross mem-
bers and rear section, together with a number of reinforc-
ing plates and beams. The front floor section, also called
the engine compartment floor, is welded at the dash panel
to the center section, which forms the floor of the Passen-
ger compartment. The rear section forms the floor of the
trunk compartment. The center and rear floor sections
are joined by a cross member forming a tunnel for the
rear axle.
Body insulation
The underbody, i.e. the floor, wheel housings and fenders,
is sprayed with a sealing composition which serves to pro-
tect the metal from flying stones and rust and to insulate
the body from road noise.
The upper surface of the floor in the passenger and trunk
compartments is covered with an asphalt mat. This is laid
before the body goes into the lacquering oven and there-
fore melts on to the steel, providing excellent rust pro-
tection and contributing to the sound insulation.
The rear wheel housings and fenders are covered with plas-
tic coating asphalt matting. Thick asphalt matting faced
with nylon fiber matting is bonded to the parts of the front
wheel housing that lie inside the Passenger compartment.
The dash panel and engine compartment are insulated with
glass wool, and the roof is insulated with foam plastic.
As from the 1973 model the roof is insulated with pressed
glass wool. Waffleboard is bonded to the insides of the
doors and valances.
Jen. 1973 SAAB 800-1
Page 596
BODY ASSEMBLY available as a replacement part, but in addition, certain
“economy spares” are stocked. Examples of these are the
General front ends of fenders, the front end of the engine compart-
ment floor, and a divided rear valance. For details, see the
If any part of the body is deformed in a crash and the dam- Spare Parts Catalogue.
age is so extensive that the part cannot be straightened out,
it can be exchanged for a new part instead. Indeed, in many
cases of minor damage it may actually prove quicker, cheap-
er and more satisfactory to renew all or part of the dam-
aged section rather than straighten it.
The pressed section with reinforcements will normally be
11
EXAMPLE OF INTEGRAL BODY DETAILS AVAILABLE AS SPARE PARTS
1. Front floor (engine compartment floor) 18. Scuff plate, inner part
2. Front floor front part (economy spare part) 19. Scuff plate, outer part
3. Floor member 20. Rear wheel housing cpl.
4. Front wheel housing cpl. 21. Rear wheel housing, outer part
5. Front wheel housing outer part 22. Outer valance
6. Front fender 23. Outer valance front part (economy spare part)
7. Front fender front part (economy spare part) 24, Outer valance rear part (economy spare part)
8. Dash panel, lower part 25. Side member
9. Dash panel, upper part 26. Cross member
10. Windshield member 27. Rear floor
11. Roof panel 28. Rear plate
12. Roof members 29. Outer valance, Saab 99 Combi Coupé
13. Side members 30. Valance, front part, Saab 99 Combi Coupé
14. Water channels (economy spare part)
15. Front pillar 31. Valance, rear part, Saab 99 Combi Coupé
16. Plate front pillar (economy spare part)
17. ‘Rear pillar
810-1 SAAB
Dec. 1975
Page 597
Alignment jig for accident-damaged bodies Trueing-up tool
An alignment jig with trueing-up tools and accessories to The trueing-up tool is used to straighten out deformed
fit both Saab 95/96 and Saab 99 cars has been designed portions of the car body. It consists of a lever which is
to facilitate the repair of car bodies damaged in road ac- secured at the bottom by a chain to two of the legs of
cidents. the alignment jig. A hydraulic pressure cylinder is attached
to the middle of the lever, and a draw chain is attached
to the top. This arrangement makes the tool compact
(and easily portable) and also allows the direction of pull
Alignment jig to be varied within very wide limits. Neither the align-
ment jig nor the trueing-up tool need be anchored to
The alignment jig consists of a rigidly constructed frame the floor.
with plane surfaces containing a series of precision-drilled Before the trueing-up tool is used it is mounted on the
holes. Fixtures for accurate location of body parts can be alignment jig in the following manner:
screwed into these holes. Special checking fixtures are 1. Select the desired direction of pull, first laterally by
also provided; these are placed on top of the locating fix- positioning the trueing-up tool accordingly, and then
tures. When the car is set up on the alignment jig, it is pos- vertically by attaching the draw chain at a suitable
sible with the help of the checking fixtures to measure height on the lever.
any deformation of the chassis attachment points without 2. Secure the trueing-up tool to the alignment jig by
having to remove parts of the chassis. fastening both ends of the anchor chain to two of
The alignment jig is provided with a pair of wheels to the legs of the jig in such a way that tension will be
make it mobile. It need not be secured to the floor, but applied to both halves of the chain.
when in use it should be placed on a level surface with 3. Place the pressure cylinder against the pressure beam
the wheels removed. and alignment jig, first locating it laterally with re-
spect to the jig so that the cylinder comes just about
vertically below the draw chain. Then adjust the verti-
cal position of the cylinder on the lever so that the
lines of the draw chain and pressure cylinder, if ex-
tended, will intersect at the same point on the floor
or will be almost parallel (see illustration).
4. Adjust chain lengths as necessary, prize apart the
quick-release extension of the pressure cylinder, and
wrap the safety chain one turn around the beam of
the alignment jig.
ALIGNMENT JIG
$4088
APPLICATION OF TRUEING-UP TOOL
Application of trueing-up tool
The draw chain and hydraulic cylinder must be placed so
that the extended lines drawn through them intersect at
the same point on the floor or are nearly parallel. There
are then no free forces tending to lift the tool or the align-
ment jig.
Sept. 1973 SAAB 810-2
Page 598
Description of alignment jig and trueing-up tool
A description of the alignment jig and accessories and
trueing-up tool is available and can be ordered from
Saab-Scania in Nyképing under the order number
101733.
TRUEING-UP TOOL
1, Draw chain 4. Lever
2. Anchor chain 5. Pressure beam
3. Pressure cylinder 6. Hand pump
Hoisting gear, etc.
Before the alignment jig can be used, the car body or
complete car must be lifted on to it. The best method is
to use a fork-lift trolley or overhead traveling crane.
If these are not available, the job can be done with a
high-lift garage jack and a mobile collapsible trestle set
consisting of four legs on wheels and two cross-pieces.
The trestles can also be used for assembly and disassembly
work on chassis, etc. and for blocking up and moving cars
with the wheels off.
The procedure for mounting the car body on the jig is as
follows:
Place the cross-piece on the jack and then push the latter
under the car from the side at the rear edge of the thresh-
old. Raise the rear of the car so that the legs can be fitted
to the cross-piece. Then repeat the same procedure at the
front. The car can then be maneuvered over the jig with
the trestle legs straddling the jig and lowered into position
with the jack.
A suitable bench or platform about 450-600 mm 1 1/2—
2 ft.) high should be available for work on the roof of the
car or upper parts of the body.
810-3 SAAB Dec. 1975
Page 599
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Front fender fixture
Front fender fixture No. 829063 is intended for checking
and location of the front fender in connection with colli-
sion damage repairs.
Figure 1 illustrates how it is used.
The fixture also has locating studs for the Purpose of
checking the position of the top hinge attachment in the
windshield post. A ruler is first placed as shown in Fig. 2
to check the vertical position, and then is shown in Fig. 3
to check the horizontal position.
FRONT FENDER FIXTURE, FIG. 1
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Fig. 2
FRONT FENDER FIXTURE, FIG. 2 AND3
1. Hinge screw
2. Plate nut for hinge screw
3. Locating stud
4. Ruler
5. Front fender fixture 829063
Sept. 1973 SAAB
810-4
Page 600
Checking body dimensions ings and the attachment points of the suspension and power
unit. Diagonal measurements should also be made to check
If any part of the body has had to be renewed or straightened, _ that there is no residual skew or asymmetry after repairs.
it is important to check the measurements of the door open-
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REFERENCE DATA FOR CHECKING BODY DIMENSIONS
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810-5 SAAB Sept. 1973