Page 391
INSTALLATION
oN
Check that the inner universal joints are filled with
the appropriate grease. The joints must be comple-
tely filled with grease upon assembly,
Lift the power unit into the engine compartment,
using the lifting hook, tool 78 62 022.
Lower the power unit so far that the engine brackets
are about 2 in. (50 mm) from the engine cushions.
a. Place the T-pieces of the drive shafts in the inner
universal joints. Do this with the T-pieces located
vertically and with the power unit pushed over
as far as possible in the opposite direction. As-
sembling is done first on the left side and then on
the right.
b. Align the power unit to the rear engine bracket.
Lower the unit into position and tighten the front
engine cushions.
Fit the engine side support and tighten it up when
the engine is in place.
Lower the car onto the wheels.
Fit the clamps round the inner universal joints.
Tighten the bolt for rear engine bracket.
er is missing, there is a risk that the cooling fan will
collide with the radiator if the brakes are powerfully
applied.
NOTE
Check that the limiting washer on the rear of the en-
gine bracket is in position. This washer serves to limit
the forward movement of the power unit. If the wash;
10.
11,
12.
13.
14,
15.
16.
17,
Refit the rubber plug and put back the floor mat.
As from mode! 1971: Refold the insulating felt and
refit the warm air channel. Put back the floor mat.
Reconnect the speedometer cable and the freewheel
control to the gearbox.
Refit the gear shift rod joint.
Refit the clutch cylinder, together with any shims.
Adjust the clutch.
Reconnect the exhaust pipes to the cylinder heads.
Fit new gaskets.
Refit the clamps for the exhaust pipes and the sus-
pension under the car.
Reconnect the throttle control.
Reconnect all hose and cable connections to the en-
gine.
CAUTION
Do not confuse the cables to the alternator, as this
may result in ruining the latter. First connect the
black leads to D—, whereafter there will be little
risk of intermixing the other cables.
Febr 1977
bei
18. Refit the air cleaner.
19. Refit the radiator and the expansion tank. Connect
the lower coolant hose before tightening the two
lower retaining screws.
20, Connect the upper coolant hose.
21. Refit the front panel and the radiator clamping
straps.
22. Refit the radiator stays and the hood lock.
23. Reconnect the headlight and direction indicator
cables, Refit the windshield washer container and
the washer pump.
24. Refill the cooling system and bleed the system.
25. Check the gearbox oil level. Top up if necessary.
26. Check the engine oil level. Top up if necessary.
27. Reconnect the earth cable to the battery and refit
the hood.
28. Check the headlight alignment. Adjust if necessary.
29. Teststart engine. Note the oil pressure and coolant
temperature, Check the coolant level when the en-
gine has been run up to the warm condition.
30. Take the car out for a test run.
DIVISION OF ENGINE — GEARBOX
Disassembly
1. Remove the flywheel guard plate from under the
clutch housing.
2. Back off the screws between the engine and the trans-
mission.
3. Remove the starter.
4. Separate the engine from the gearbox.
Reassembly
1. Reinstall the gearbox, checking that the guide sleeves
take up the correct positions in the clutch housing.
2. Tighten the screw for the clutch housing uniformly
and with the correct torque.
3. Refit the guard plate for the flywheel.
470—3
Page 393
DISASSEMBLY, REASSEMBLY
DISASSEMBLY
Proceed step by step as described in the following until
the part concerned has been removed.
1.
Clean the outside of the transmission unit and drain
off the oil.
Remove the inner universal joints and shafts. See
section 473.
Separate the transmission at the joint between the
clutch housing and the transmission case. After hav-
ing removed all the screws, the clutch shaft will
have to be turned to a specific position to allow
separation of the cases. Therefore, turn the clutch
shaft to locate this position while removing the
clutch housing.
Remove the transmission case cover together with
the gear shift fork shaft.
Fit the transmission case in the fixture, tool
78 41 000.
TRANSMISSION CASE HELD IN FIXTURE
Too! 78 41 000
DISASSEMBLY OF DIFFERENTIAL
1, 3. 4. Spacer rings and shims
2. Differential case
5. Bearing caps
SAAB
Febr 1977
Differential and freewheel
NOTE
Before continuing to dismantle the transmission unit,
always check the location of the pinion and measure
the ring gear clearance to ascertain if the setting has
been incorrect.
Release the two bearing caps and lift out the differ-
ential assembly. Collect the spacers and shims out-
side the bearings for subsequent refitting, provided
that differential backlash has not been altered by
the fitting of a new part. Disassembly of the differ-
ential is described in section 473.
471-1
Page 394
/. Remove the freewhee
(hub from the freewhee
sleeve, using tool 87 90 305 tlie °
DISASSEMBLY OR REASSEMBLY OF FREEWHEEL HUB
Tool 87 90 305
10,
Take the needle bearing out of the fraewheel sleave
Check that none of the rollers is missing If the pin
ion shaft or bearings are to be dismantled, measure
the location of the shaft before removing the end
cover, See section 473
Gear shift forks
Back off the end cover bolts and drive out the 1st
2nd and 3rd—4th gear shift fork shaft from the front,
using an arbor or similar tool,
When the cover is free, take it off rearwards, keep
ing the gear shift forks in position and preventing
them from tipping on the shafts,
Note the location of shims in the cover and collect
the shims,
Take care to prevent ejection of the poppet balls
in the gear shift forks,
DISASSEMBLY OF END COVER AND SHIFT FORK RAILS
471-2
Febr 1977
Page 395
11.
12.
13.
If only the rear pinion shaft bearing is to be re-
moved, this can be done now as follows: Engage
two gears (reverse and 3rd), release the retainer and
back off the left hand threaded end nut on the shaft
whereupon the bearing can be removed with the aid
of puller 78 41 15 . As from transmission No.
F 39522, a new rear pinion bearing with a split in-
ner ring has been introduced, This bearing has to be
removed in two stages.
Pull the bearing off the shaft, using puller 78 41 158
and then remove the inner part of the inner ring,
which remains on the shaft, using puller 78 60 521.
A new bearing can now be fitted and the pinion
shaft shimmed.
Release the reverse gear shift fork shaft from the
rear by means of a brass arbor or similar implement
and withdraw it forwards. Collect the poppet ball
in the gear shift fork.
Lift out the three gear shift forks,
Countershaft with bearings and gears
14.
15.
Engage two gears simultaneously, e.g. reverse and
3rd.
Back off the nut on the front end of the counter
shaft. Remove the friction wheel and friction wash-
er. Back off the end nuts of the pinion shaft and/or
primary shaft if these items are also to be removed.
As from transmission No. 108911, an oil cup is fitted for
lubrication of the counter shaft. This must be removed
before the end nut. When removing the end nut, tool
78 61 321 will be used.
NOTE
The pinion shaft nut is left hand threaded.
16.
17.
Return the synchronizer sleeve to the neutral posi-
tion.
Locate arbor 78 60 588 fitted with the shortest
point between the front press screw and the coun-
ter shaft and press in the shaft until the arbor rests
against the gear wheel.
Meanwhile, the dolly 78 41
between the 1st speed gear and th
the transmission case.
Change the arbor point to the next longer one and
press the shaft in again. Repeat the procedure with
the longest point until the bearing a
gear are released.
257 should be located
e rear end wall of
nd counter shaft
Febr 1977
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3:
7841257 L
| 7841000
DRIVING OUT COUNTER SHAFT
Tools 78 41 000, 78 41 257 and 78 60 588
LOCATING OF HOLDING-UP TOOL DURING DRIVING-OUT
OF COUNTER SHAFT
Tool 78 41 257
18. Pull the shaft out rearwards, whereupon the coun-
ter shaft gear will be released, Collect the spacer and
key for the countershaft gear.
If necessary:
a, Remove the retaining ring from the shaft and
drive off the rear ball bearing and the bearing
seat, enabling the reverse gear to be removed.
b. The front counter shaft bearing cannot be
changed without removing the primary shaft.
471-3
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Say
Page 396
Primary shaft with bearings and gears
19. Back off the Primary shaft end nut and remove the
retaining washer,
20. Place arbor 78 41 040 between the rear press screw
and the shaft, and press the shaft out.
7841000
DRIVING OUT PRIMARY SHAFT
Tools 78 41 000 and 78 41 042
21. Lift out the shaft, gear and synchronizer as a single
unit.
22. When the primary shaft has been removed, the
front bearing of the counter shaft is released and
can be removed by gently tapping it out with a fi-
ber mallet towards the differential side.
23. Drive out the rear primary shaft bearing, using the
front press screw, tool 78 41 091 and the extension
sleeve 78 41 067.
If necessary:
a. Remove the thrust washer and locking pin from
the shaft.
b. Remove the retaining ring from the shaft and
drive off the front bearing with the aid of dolly
83 90 098 and the ring halves 83 90 080.
Pinion shaft with bearings and gears
NOTE
The rear pinion shaft bearing can be removed sepa-
rately for bearing renewal or pinion adjustment as
soon as the end cover has been removed, i.e. with-
out removing the primary shaft and counter shaft.
24, Remove the speedometer drive gear.
471-4
——_
Remove the left hand threaded end nut from the
shaft and pull out the rear pinion shaft bearing With
the puller, tool 78 41 158, using the front press
screw to support the shaft. Collect the spacer and
shims from inside the bearing.
ca
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25.
7841158 |
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7841000
DRIVING OUT PINION SHAFT BEARING
Tools 78 41 000 and 78 41 158
As from transmission No. F 39522, a new rear pinion
bearing with a split inner ring has been introduced, This
bearing has to be removed in two stages. Pull the bearing
off the shaft, using puller 78 41 158, and then remove
the inner part of the inner ring, which remains on the
shaft, using puller 78 60 521.
26. Locate the supporting tool 78 41 216, on the low-
er side of the shaft between the rear gear wheel and
the front end of the case. Make sure that the tool is
centered on the gear wheel so that the gear does not
tip on the shaft.
i
—
= 7841216
\y
Nie i | 7
7841000
DRIVING OUT PINION SHAFT
Tools 78 41 000 and 78 41 216
Febr 1977
Page 397
27. Press the pinion shaft out in the f
Lift the 3rd gear out of the trans
drawing the shaft at the same ti
lf necessary:
Hi
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¢
DRIVING OUT THE PINION SHAFT
a. Press the front roller bearing and pinion shaft 4th
gear from the shaft, proceeding as follows:
Remove the retaining ring from the roller bearing,
if the latter is to be refitted. If the bearing is to be
rejected there will be no need to remove the ring.
Place the pinion shaft and the supporting tool
78 41 232 in an arbor press and drive out the
shaft. Make sure that the outer bearing race is
flush against the gear wheel.
.
PRESSING OFF THE FRONT PINION SHAF
4TH GEAR IN A PRESS
Tool 78 41 232
Febr 1977
—2
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——————
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==
T BEARING AND
Orward direction.
Mission Case, with-
me.
\
\
The bearing should on no account be taken apart,
if it is to be refitted. See to it that the rollers do
not fall out and refit the retaining ring immedi-
ately, expanding it first so that it springs proper-
ly in the groove.
b. Press the oil collector gently out of the transmis-
sion case.
-—
NOTE
When installing new gears in the transmission unit,
remember that the 3rd speed gear and pinion shaft
3rd gear are supplied in matched sets, as are the 4th
speed gear and the pinion shaft 4th gear. Quiet opera-
tion is ensured only if both the gears in the set are re-
newed at the same time. The pinion shaft and ring
gear are also matched and must be changed in pairs.
SAAB 471-5
abeeneen
===
Page 398
REASSEMBLY
When the part concerned has been removed, clean the
cover dividing plane and remove any gasket fragments
and residual sealing compound. Inspect and clean all dis-
assembled parts, as well as the transmission case, in kero-
sene or the like. Make sure that such items as poppet balls,
needles from broken bearing, etc., are not left in the case.
Then commence reassembly at the appropriate point in
the following description.
Pinion shaft with bearings and gears
1. Using an arbor press and tool 78 41 067 drive the
roller bearing and pinion shaft 4th gear in until the
inner bearing race is flush with the pinion gear.
Mount the spacers and speedometer drive on the
pinion shaft.
On earlier gear units make sure that the matching
number faces the same way as on the 4th speed
gear. On later gear units there are no matching
number. The 4th speed gear is marked with a X on
that side, which will face from the gear end of the
pinion shaft.
2. Next, pass the pinion shaft through the end of and
into the transmission case from the differential side,
and then locate the pinion shaft 3rd gear on the
shaft inside the case. Make sure that the Woodruff
key for the 3rd gear has been fitted to the pinion
shaft. In some older units, the pinion shaft 4th
gear is also held by a Woodruff key instead of
being press fitted.
3. Turn the shaft to align the Woodruff key in rela-
tion to the groove in the 3rd gear.
4. Insert the guiding arbor 78 41 224, in the rear bear-
ing seat so that the pinion shaft passes into it.
5. Secure the arbor with the rear press screw so that
its flange is flush against the transmission case end.
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7841000
DRIVING IN PINION SHAFT
Tools 78 41 000 and 78 41 224
Drive the pinion shaft finally home with the front
6. press screw, checking that the key engages in the
pinion shaft 3rd gear.
7. Back off the rear press screws and remove the arbor
from the bearing seat.
8. Place an 0.14 in. (3.6 mm) spacer on the shaft eng,
NOTE! if the rear pinion bearing is equipped with split
inner ring the spacer washer has to be placed next to the
g. The washer diameter will be 1.4 in. (36 mm).
bearin
NOTE
If no part of the pinion shaft assembly has been re-
newed, the previously used spacer and shims may be
refitted.
9, Using the press screw and arbor 78 41 224, press
the rear ball bearing, complete with retaining ring,
into the transmission case end. Use the press screw
at the front end of the pinion shaft as a support
during this operation.
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7841000
DRIVING IN PINION SHAFT BEARING
Tools 78 41 000 and 78 41 224
In case of a split bearing, fit the inner ring first and
then the principal part of the bearing on the shaft.
Then Press the bearing in, as described above.
Fit a new tabbed washer and lock nut (NOTE! Left
hand threaded) on the pinion shaft. Note that the
nut should not be tightened until the primary- and
counter shaft are installed. See position 26.
10.
Febr 1977
Page 399
primary shaft with bearings and gears a :
1 ly |
11. Upto and incl. gear box 276503: | D
Refit the front bearing (using tool 78 41 075) and a [| se | =
place the retaining ring, locking pin, thrust washer | ' 7841042
and 4th speed gear needle bearing on the primary 7841141
shaft. Check that the locking pin prevents the
thrust washer from rotating,
As from gear box 276504: \ M. | | /
Fit the oil thrower and the front bearing (using tool NN | ar f |
78 41 075) and place the retaining ring, washer and : Ni | Ie
4th speed gear needle bearing on the primary shaft. \ l
12, Before pressing in the primary shaft, the counter
shaft front bearing must be placed in position. Press 7841000 |
the bearing in from the front with the aid of the
arbor 78 61 347, until it rests hard against the re-
taining ring in the bearing seat. DRIVING IN PRIMARY SHAFT
Tools 48 41 000, 78 41 042 and 78 41 141
-~-o i mete)
m= ea ae 7.
I ly I 1 17. Remove the aligning arbor from the 3rd speed gear
» | | and locate the needle bearing, spacer sleeve and
; bushing for this gear on the shaft inside the gear
hub,
lo = 18. Place the spacer — with the bevelled side facing out-
7861347 wards — and the rear bearing on the primary shaft,
’ and then drive the bearing in with tool 78 41 091.
: | | Note that the front press screw and the arbor in
iy ft gl the freewheel sleeve serve to hold up the shaft.
vl \ ee ae? ' ao
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7841000 sand: oS
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DRIVING IN COUNTER SHAFT BEARING 7841091 7841042
Tools 78 41 000 and 78 61 347
a , 4
: \ \ | /
13. Assemble the primary shaft components, the 3rd | \ | af y, |
and 4th speed gears together with the synchronizer \l | | | 7
sleeve and rings, and lift the entire assembly into
the transmission case while passing the aligning ar-
bor 78 41 141 into the 3rd speed gear through the
rear bearing seat, and secure the arbor with the
press screw.
14. Pass the shaft in carefully from the front until its
splines enter the synchronizer hub.
15. Fit the arbor 78 41 042 into the freewheel sleeve.
7841000
DRIVING IN PRIMARY SHAFT BEARING
Tools 78 41 000, 78 41 042 and 78 41 091
NOTE “
The needle bearing must be removed from the free- :
wheel sleeve while this is being done.
Place a new tabbed washer, with the tab facing out-
wards, and a nut on the shaft. Do not tighten the
nut with a torque wrench until the counter shaft
has been refitted. See point 26.
16. Using the press screw, drive the primary shaft care-
fully in against the arbor in the freewheel sleeve un-
til the 3rd speed gear rests against the rear end of
the case. Check that the synchronizer hub does not
tip,
FE
ebr 1977 471-7
Page 400
Countershaft With bearings and gears
20.
21.
22.
Place the countershaft gear wheel in its correct posi-
tion with the machined part facin
g the clutch hous-
ng. The front Press screw and tool 78 61 347
should hold the counter shaft gear and bearing in
place.
Reassemble the ist and 2nd speed gears, the latter
complete with needle bearing, spacer and bushing,
and the synchronizer unit with its rings.
Lift this assembly into the tra
the countershaft, complete with the 1st speed gear
needle bearing, through the rear end of the trans-
MiIssiON Case at the same time.
As from transmission No, 10891 1, the 1st and 2nd
speed gears are splines mounted,
nsmission case, passing
NOTE
If the rear bearing, bearing seat and reverse gear have
not been removed, they may remain on the shaft
during reassembly. In this case, however, the bearing
must first be pressed into the seat and the rear retain-
ing ring removed from the shaft.
If the countershaft is refitted complete with reverse
gear and bearing, use tool 78 41 091. This tool is a}-
50 to be used if the reverse gear and the seat with the
bearing are mounted separately,
———___
NOTE
25.
26.
|
Engage two gears simultaneously, e.g. 2nd and 4th,
and turn the 3rd speed gear in order to align the
key grooves in the counter shaft and the counter
shaft wheel. Drive the key in with an arbor.
Refit the friction wheel together with a new fric-
tion washer and star washer. Tighten the counter
shaft end nut with a torque of 80 Nm (60 ft.|b.,
8 kpm). The primary shaft and pinion shaft nuts,
the latter left hand threaded, should also be tight-
ened with a torque wrench at this stage.
Tighten the pinion shaft nut initially with a torque
of 120 Nm (90 ft.lb., 12 kpm), back off, and re-
tighten with a torque of 60 Nm (45 ft.lb., 6 kpm),
The primary shaft nut is to be tightened with a tor-
que of 50 Nm (35 ft.lb., 5 kpm).
23.
24.
gear and the front ball bearing. Then pass the shaft
through the front bearing and into the counter shaft
gear wheel.
Drive the countershaft in with the Pass screw and
tool 78 41 091. Inso doing, make sure that the
shaft splines engage with the synchronizer hub and
that the shaft passes into the countershaft gear,
Use the peg wrench 78 41 240, to turn the shaft.
Refit the retaining ring for the rear bearing after
pressing home.
i! IP 1] |
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7861347
VY /
7841000
DRIVING IN COUNTER SHAFT
Tools 78 41 000, 78 41 091, 78 41 240 and 78 61 347
471-8
Place the spacer on the shaft between the 2nd speed
Check that the friction wheel is not located outside
the opposing gear and that there is sufficient clear-
ance between the primary shaft ball bearing and the
counter shaft gear. See ‘Friction brake’.
NOTE
27.
Secure the nuts on the main- and pinion shaft. The
main shaft lock washer tab is bent over the nut.
The pinion shaft nut is locked as follows:
a. Use the press screw as dolly against the front end
of the pinion shaft so that a small clearance is ob-
tained between the flange ring on the rear pinion
bearing and the gear box cover. Thereby preven-
ting damage to the bearing when the nut is up-
set.
b. Upset the nut collar in the three recesses in the
lock washer with a rounded drift.
If the pinion adjustment is not already correct,
leave the pinion shaft nut unlocked until adjust-
ment is carried out.
Febr 1977