Page 51
WARNING SYSTEM FOR UNFASTENED SEAT BELT
Up to and incl. chassis Nos. 99752026344 resp.
99757000072
A device which prevents the engine from starting and a
buzzer and a warning lamp are actuated if the driver and/
or the front seat passenger has not fastened his safety
belt. The following components are included in the warn-
ing system:
Buzzer — under the instrument panel
Warning lamp — on the instrument panel
Start inhibitor relay — next to the fuse box in the engine
compartment
Seat contact — in the driver's seat
Seat contact — in the passenger's seat
Belt contact — in the flap lock
Handbrake contact — (manual transmission)
Gear selector lever contact — (automatic transmission)
Logic unit — under the rear seat cushion
LOGIC UNIT
The warning system is controlled through a logic unit to
which all the components in the system are connected,
The control circuit to the starter motor is broken when
the driver or front seat Passenger actuates his seat contact
but has not fastened his seat belt. As soon as the belt is
fastened, the starter motor is reconnected. The signals to
the logic unit from the seat contact and the belt contact
must be received in the right order. This prevents tamper-
ing with the system.
The buzzer sounds and the warning lamp lights up if the
ignition is on and:
a. (manual transmission) the handbrake is released
b. (automatic transmission) the gear selector lever is
moved from the “P” position
and the driver or the front seat Passenger actuates his
seat contact without having fastened his seat belt.
Wiring diagram, see section 371,
Sept. 1975
SAAB 364-5
As from chassis Nos. 99752026345 resp. 99757000073
The warning system consists of a warning lamp and a
buzzer.
The warning lamp lights if the ignition is on and the seat
belt is unfastened.
The buzzer sounds 4—8 seconds if the ignition is on and
the belt is unfastened.
72 ig? SV O75
166 GL G75
231 RD O75 7 ii
aN 245.S¥ 075 Te-sy_234 BROS __|
i 1 * —* 233 GN/VT O75
oo} 235 SV O75 232 SV 075 Vat
— Sie
ELECTRICAL DIAGRAM
22. Fuse No, 3
70. Seat belt contact (in the flap lock)
72, Warning lamp (in the instrument panel)
82, Logic relay with buzzer (under the rear seat)
at ta
a aaamnmetty we
Page 52
ee
CLUTCH CONTROL
REMOVING AND INSTALLING THE CLUTCH PEDAL
|. Remove the split pin and washer and pull out the
shaft bolt for the master cylinder push rod.
. Unhook the clutch pedal return spring.
. Remove'the axle bolt and the pedal.
. Remove the spring If necessary.
. Lubricate the pedal. bearing with chassis grease before
reassembling.
me wh
Reassembie in the reverse order.
ADJUSTING CLUTCH PLAY, MODEL 1975
The clutch play, i.e. the clearance between the release
bearing and the diaphragm spring, is requiated by an
adjusting screw that threads into the transmission case
and acts as the fulcrum of the olutch fever, The gap is
increased when the screw is backed off. The gap should
be checked at the otiter end of the'clutch lever {see illus-
tration), where it should be 0,12 + 0,02" {2+ 0.5 mm).
ADJUSTING THE CLUTCH PLAY
REMOVING THE RELEASE BEARING (AND CLUTC
LEVER, MODEL 1975)
To remove the release bearing of clutch lever, proceed in
the same manner @s when removing the clutch.
The release bearing is removed together with the clutch
and slave cylinder (quice:sieeva}
MASTER CYLINDER
General
The master cylinder is placed under the servo unit-and is
actuated by a push rod from the clutch pedal: In the cy!
inder is besides the push rod, piston, piston seals and re.
turn spring. The clutch fluid container is incorporated in
the brake fluid container completely separated from the
brake tluid. From the container a hose leads to the cluteh
cylinder,
Removal
1, Detach the clamp holding the pipe from the clutch
cylinder at the body and remove the pipe at the cyl
inder,
2. Remove the left hand screen under the instrument
panel,
3. Remove the pin holding the push rod to the clutch
pedal.
4. Remove the nuts inside the dash panel and remove the
clutch cylinder from the engine compartment. Pull off
the hose from the fluid container and Hang it upso
that the fluid is not: coming out.
Disassembling
Pull back the sealing bellows and remove the lock ring
with & pair of pliers. Take out the:push rod with the
washer. The piston and its seal is now visible. Remove
the piston, washer; piston seat and spring. Take the seal
CLUTCH MASTER CYLINDER
1, Housing 4, Washer
2. Spring with seat 5, Piston and rear eaal
3. Sealing 6. Push rod with stop washers, lock ring anc bella
SAAB 412-1
Page 53
OO
carefully off the piston, Examine the cylinder walls: if
they are smooth and unscratched, new seals can be fitted,
bur jf the surface of the cylinder bore is rough, a com-
plete new cylinder should be installed. tf the old seals on
the piston are-eniarged or swollen, they are probably
contaminated with mineral oil; this is the most common
cause of cylinder malfunction. Seals made of natural
rubber are very sensitive to mineral oil, and even smal!
quantities of ofl can cause them to swell with time. tf
this is suspected, change all the seals and flush the sys-
tem with clean hydraulic brake fluid.
Assambling
Fit the return spring with jts retainer, Lubricate the pis:
ton and seals thoroughly with Girling Rubber Grease 3
and fit the packing, washer and piston with seals,
NOTE
The washer must be fitted with the convex side
facing the piston (see illustration).
S 4539
CORRECT POSITION GF THE WASHER
Fit the push rod inte the-cylinder, followed by the wash-
er and lock ring, which are located |n the cylinder hous-
ing groove. Replace the seating bellows or fit a new bel-
lows if the old one is damaged,
Installation
1. Cannect the hose from the container to the eylinder,
2, Put the cylinder in place and install the nuts from in-
side the car,
3. Connect the push rod to the pedal,
4. Install the left hand screen under the instrument panel,
5. Connect the clutch pipe, fill fluid and-bleed the system.
SLAVE CYLINDER, MODEL 1975
General
The siave cylinder consists of s cast-iron housing with an
operating unit consisting of a push rod, fock ring and pis-
ton, A rubber cap seals the end of the push rod. The cyl- PF) {
inder housing js provided with a bleeding nipple.
SLAVE CYLINDER, MODEL 1975
1, Push rod 4, Pistori
2. Staling cap 5. Pistan seal
3. Lock ring 6. Housing
412-2 Ass }
Page 54
a
SLAVE CYLINDER, AS FROM MODEL 1876 spring of the clutch. When the pedal is released, the re-
lease bearing-and pistons are returned by means of the
The slave cylinder isan annular hydtaulic cylinder diaphragm spring. Further return of the piston is pre-
mounted inside the clutch cover and enclosing the ctutch vented by the friction of the lip seal in the slave cylinder
shaft. The slave cylinder consists of an outer cylinder and by a sliding lock ring on the stave cylinder piston.
housing and an internal sieeve, betwean which there is at This means that when the clutch pedal is-in the rest pasi-
annular piston and 8 lip seal. The release bearing |s Jacked tion, the release bearing is in cantact with the diaphragm
to the piston by means of am-O-ring and a lock ring. spring. Adjustment of the clutch |s automatic owing to
When tie clutch pedal is depressaci, the slave cylinder pis- the fact that the sliding lock ring on the piston moves
ton and release bearing act directly on the diaphraym along the piston in pace with the wear to the clutch fining.
5 1
| 4 3
6
aawe
SLAVE CYLINDER, AS FROM MODEL 1976
1. Slave cylinder housing
2. Sleeve
3. Piston
4, Lin seal
5, O-ring
6. Retoasp bosti ny
7. O-ring
8. Lock rine
9. Lock ring 7
SAAB 412-3
Page 55
DISMANTLING THE SLAVE CYLINDER
1. Remove the release bearing from the slave cylinder.
2. Press out the slave cylinder sleeve and remove the O-
ring from the flange of the sleeve.
|
PRESSING OUT THE CYLINDER SLEEVE
3.. Remove the piston and lip seal,
ASSEMBLY
Make dure that the slave oylinder has been thoroughly
cleaned, Wash the parts in brake fluid of a special cleaning
fluid for hydraulic brake components, e.g. a mixture of
cleaning spirit and acetone.
Thoroughly clean the siave cylinder using @ mixture of
70 % cleaning spirit and 30 % acetone.
The lip seal should never be allowed to come into contact
with mineral oil, Apply a thin coating of Castro! Rubber
Grease to the lip seat (not in the groove) and to the piston
(but not the O-ring).
1. Fit the O-ring to the flange of the sleeve.
2. Slide the lip seal onto the sieeve. Dip the flange of the
sleave in brake fluid and insert the siesve into the cy!-
inder, Insert the lip seal part of the way into the cy!
inder.
THE SLEEVE IS GUIDED BY THE PISTON
3. Guide the sleeve and the cylinder upwards. by pushing
in the piston. The two.lock rings and the O-ring should
be fitted to the piston.
4 Place the slave cylinder on 2 suitable support (¢.9. 4
1
1
| eZ
PRESSING THE SLEEVE INTO THE CYLINDER a
J
spare slave cylinder piston) dnd press the sleeve into
the cylinder.
6. Fit-the release bearing to the piston, ensuring that the
bearing is turned the right way {see illustration).
$6239 v
fr,
POSITIONING THE RELEASE BEARING
BLEEDING THE MASTER AND SLAVE CYLINDER
1. Connect a-hose (about 1/4’ or 6 mm IB) to the slave
cylinder bleeder nipple; and place the free end ina
collecting vessel part-filled with hydraulic brake fluid.
9. Fill the master cylinder header tank with brake fluid.
412-4 SAAB
Page 56
MASTER CYLINDER, CLUTCH
"A Master cylinder, clutch
“B’ Container for clutch fluid {combined with brake
fluid container}
3. Open the bleeder nipple on the’slave evlinder a half
turn,
4. Place the coolant system tester over the filler opening
of the master cylinder {see illustration}.
BLEEDING THE CLUTCH SYSTEM
5. Pump one or more times until all air has been expelled
fram the system,
6. Close the slave cylinder bleeder nippie.
7, Check that all air has been expelled by pushing down
the clutch padal,
Sept, 1975 SHES
ss
——s
SS:
——
)
412-5
Page 57
TRANSMISSION, EXPLODED VIEW
1. Up to and incl. gearbox No. 81 7.000
2. As from gearbox No. 900001 resp. S 00001
Page 58
TRANSMISSION CONTROL
Manual transmission
GENERAL
Gear shifting is controlled by a floor-mounted lever fo-
cated between the front seats.
The gear lever is fitted with 4 reverse gear catch which
can be released by pulling the ring-shaped handle under
the fever knob upwards. The fever is made in two parts,
insulated from eachother by rubber bearings. The rest
of the transmission contro! system consists of-a gear lever
housing recessed into the floor between the front seats
and 8 fod that transmits gear lever movements to the
gearbox,
As from model 1980 the gear position contro! js moved
from the gear lever/housing to the gear box, Stop notches
are introduced on the gear selectors for 1st, 2nd and re-
verse gear,
The reverse gear catch is however unchanged.
ADJUSTING GEAR POSITIONS
1. Engage reverse gear end turn the ignition key to L
{Locked),
2. Move the gear lever back and forth. The gear shift rod
should then have an axial movement of 3.5 + 0.5 mm)-
Adjust by moving the gear lever housing forward or
backward,
GEAR LEVER LOCK
General
The car is equipped with @ combined ignition switch and
gear fever lock. When the gear tever is placed in reverse
and the ignition key withdrawn, the gear lever is locked.
The ignition switch has the following positions:
L. Locked. Reverse gear must be engaged before the key
con be turned to L, and the key can only be with-
drawn in this position.
Parking lights and hazard warning lights can be
switched on,
G. Garage. All lights can be switched on,
K. Drive. All electrical systems including the ignition cir-
cult are five.
§. Start, This position hes a spring-loaded return to K,
The gear lover fock consists of a tongue (3) and cogurheel
(4) nctusted by a toothed segment (5) mounted under
the lock cylinder (6), The sagment turns with the lock
cylinder,
GEAR LEVER Lock
1. Housing
2. Spring
3. Locking tongue
4, Cogwhee!
5, Toothed segment
6. Lock cylinder
IGNITION AND STARTER CONTACT
Removal
Disconnect the battery cable.
Remove the driver's seat,
Pull up the rubber bellows and fold back the floor
carpet.
Remove the fixing plate batween the heater ducts
in front of the gear lever housing,
Remove the buttons from the heater controls.
6. Remove the three gear lever cover retaining screws.
Lift the cover and disconnect the ignition lock
warning light and electrical connections-to the
switch. Remove the cover.
7, Disconnect the cables fram the ignition lock and
reversing light switch,
> ero
SAAB 4321
Page 59
LOCK CYLINDER AND KEY
1, Key
2. Lock cylinder
PRESSING IN THE CATCH PIN
1. Hole-for catch pin
2. Key
3. Look cytinder
Assembling
1. Turn the key in the lock cylinder to a position between
the locking- and garage positions,
2. Push in the lock cylinder catch pin. Check that the
toothed segment driver pins are correctly positioned
to fit in the lock cylinder. Push in the lock cylinder
and check that it is engaged in the toothed segment.
3. Mount the gear lever housing according to the instruc-
tions given below.
Disassembly when key is missing
if the key is missing, the lock cylinder is removed from
the gear lever housing as follows:
1, Lift out the left front seat and the gear lever housing
protection casing,
2. Loosen the gear lever housing retaining nuts with the
aid of special too! 8391237.
3. Drill out the plug covering the hole for the lock cyl-
inder catch pin in the gear lever housing.
4. Drive in the catch pin with the ald of a drift approx.
0.08 In, (approx. 2 mm) and remove the lock cylinder,
Before installation, plug the hole in the gear lever housing
again, The plug is made of a suitsblescrew or rivet that is
cut to a length of approx. 0,19 in. {approx. 5 mm).
THE LOCK CYLINDER CATCH PIN IS DRIVEN IN WITH THE
AID OF A DRIFT
GEAR LEVER HOUSING
Dismantling
1. Disconnect the battery cables,
2. Remove the driver’s seat,
3. Pull up the rubber bellows on the gear lever, fold up
the floor carpet and remove one of the heater duct:
from in front of the gear lever housing.
4. Remove the taper pin from the joint between the gear
shift rod and the heater ducts.
5. Remove the buttons from the heater controls,
6. Remove the three gear lever cover retaining screws,
raise the cover and remove the ignition lock warning
lamp and electrical connections to the switch. Remove
the cover,
7. Disconnect the cable from the ignition lock and revers-
ing light switch.
8. Remove the gear lever housing retaining screws using
tool 8391237 and remove the housing.
Page 60
aaa
Removing the gear lever as from chassis No. 99.039.548
. Undo the three screws under the rubber boot and re-
move the gear lever from the gear lever housing.
. Pull out the tension pin from the carrier, screw out
the catch stud and remove the spring.
. Remove the carrier, the bearing and the cover.
. Knock carefully with a plastic hammer on the knob,
so that it will loosen from the gear lever and remove
the carrier, the catch rod and the rubber boot.
. Remove the lock ring, which holds the hollow lever
and the gear lever together and pull out the hollow
lever with its rubber bushing.
Replace damaged or weared parts.
Assembly
qi
as
as
Jan. 1971
Fit slot ring, washers and rubber bushings on the hol-
low lever.
Fit the hollow lever in the gear lever and fit the lock
ring.
. Fit rubber boot, carrier and catch rod. Put the spring
into the hollow lever and screw in the catch stud 1”
(25 mm) see illustration.
. Fit cover, bearing, carrier and tension pin.
. Press the knob on the gear lever.
. Fit the gear lever on the gear lever housing.
14
15
16
18
19
23
24
25 mm
S 3190
SECTION THROUGH GEAR LEVER HOUSING, AS FROM
CHASSIS NOS. 99,039.548
PO NOE Gm oo
Knob
Carrier
Catch rod
Gear lever
Rubber boot
. Rubber bushing
Washer
Hollow lever
Slot ring
Washer
. Rubber bushing
. Washer
. Lock ring
. Cover
. Bearing
. Gear lever bearing
. Carrier
. Tension pin
. Spring
. Gear shift rod
. Catch stud
. Bottom part
. Bearing
. Rubber bushing
432-5