Page 421
Measuring and shimming
1. Locate the differential and ring gear assembly in the
bearing seats.
2. Insert a suitable spacer at the smaller bearing seat and
then fit a suitable combination of shims between the
spacer and the bearing so that roughly the correct
amount of backlash is obtained.
3, Insert the spacer and shims for the other bearing seat,
again with the shims nearest the bearing. Select a suit-
able total thickness which ensures that there will be
no axial play on the differential side, but which does
not give rise to tension between the bearings. It should
be possible to drive the spacer into its position with
thumb pressure.
4, Fit the bearing caps and tighten the bolts with a tor-
que of 40 Nm (29 ft.lb., 4 kpm).
NOTE
The screws are of different lengths for the left and
right sides.
5. Measure the backlash with the dial indicator screwed
into the holder belonging to the transmission case fix-
ture. Fit the indicator with a short measuring point
and align it at right angles to the tooth flank at the
ring gear periphery. ea A
MEASURING RING GEAR BACKLASH
Febr 1977
6. Lock the pinion shaft by passing a screwdriver OF
other suitable implement into the aperture for the
speedometer drive. Turn the rin
forth while checking the backlas
teeth must be dry and the measured bac
not differ by more than + 0.002 in. (0.0
the backlash at four more points on the ring g
7. \f the backlash does not agree with the figure
(0.15 mm) on the ring gear, remove the bearing caps
and select new combinations of spacer and shims.
Note that if shims are removed from one side, the
same thickness must be added on the other side.
h reading. The gear
klash must
ear.
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NS
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LOCATION OF SPACER AND SHIMS
1. Spacers and shims
A change of 0.004 in. (0.1 mm) in shimming results
in a change of 0.002 in. (0.05 mm) in backlash.
8. Recheck the adjustment after any changing of shim-
ming.
IMPORTANT
Before disassembling the transmission unit, always
measure the relative positions of the pinion and ring
gear, in order to determine whether the adjustment
has possibly been incorrect. If the pinion and ring
gear have been used only for a short mileage (less
than 6000 miles/10.000 km), the unit can be read-
justed. However, after longer mileages, when the
gears will have become worn in at a certain position,
adjustment should be made to agree with the read-
ings obtained prior to disassembly.
473~—7
g gear gently back and
5 mm). Check
0.006 in.
Page 422
Replacement of axial bearing DIFFERENTIAL
To change the rear axial bearing on the pinion shaft, sep-
arate the clutch housing from the transmission case and
ee ee ee ee
mount the latter in the transmission case fixture,
Removal
ls
Remove the differential and record the position of the
pinion.
2. Remove the transmission case cover and end cover,
3. Engage two gears simultaneously and back off the left
hand threaded, pinion shaft end nut.
4. Withdraw the pinion shaft axial bearing with puller
f
78 41 158. Then, if the bearing is split, remove the in-
ner ring from the shaft with tool 78 60 521, using the
ront press screw to support the shaft.
nstallation
1.
Drive the bearing into its sleeve.
2. Make sure that the shims and spacer have been fitted,
with the spacer closest to the bearing, and drive the
bearing into the transmission case with tool 78 41 224.
If a split bearing is to be fitted, place the inner ring,
followed by the outer ring with rollers, on the shaft
and then drive the bearing on with tool 78 41 224. If
a bearing of earlier design was fitted and is to be re-
placed by a bearing with a split inner ring, it will also
be necessary to change the spacer. Use the front press
screw to support the shaft.
3. Tighten the pinion shaft end nut initially with a torque
of 120 Nm (85 ft.lb., 12 kpm). Loosen the nut and
tighten again with a torque of 60 Nm (45 ft.lb., 6 kpm).
4. As the new axial bearing will have changed the adjust-
ment of the pinion as well as the pinion shaft shim-
ming in the end cover, the end cover shimming must
be readjusted. See section 471.
5. Refit the end cover and tighten the bolts with a tor-
que of 25 Nm (18 ft.lb., 2.5 kpm).
6. Measure and adjust the position of the pinion as de-
scribed in this section.
7. After final adjustment, secure the pinion shaft end
nut. Then refit the cover and tighten the bolts finally
with a torque wrench.
8. Refit the differential and transmission case cover with
the appurtenant shims. Remove the transmission case
from the fixture and refit the clutch housing to it.
473-8
DIFFERENTIAL
Disassemoly
If is not necessary to fix the transmission case in the fix-
ture in order to disassemble the differential, although
doing so would facilitate checking and adjustment of
ring gear backlash.
NOTE
To renew parts inside the differential assembly, only
the two long ring gear bolts which lock the differen-
tial pinion shaft need be removed. The shaft and the
pinions can then be removed without disassembling
the differential.
1. Remove the universal joints and clutch housing.
2. Remove the differential bearing caps and lift out the
differential assembly. Collect the spacers from outside
the bearings.
3. If necessary, drive both bearings off the differential
assembly.
4. Back off and remove the ring gear bolts and remove
the ring gear.
. Drive out the differential pinion shaft.
6. Remove the pinions and gear wheels from the differen-
tial. Remove the retaining rings or circlips from the
differential wheels.
a
Febr 1977
Page 423
Reassembly
[ IMPORTANT
The ring gear must not be changed without fitting
a new pinion shaft, since these two Parts are sup-
plied in matched sets.
1. Change all worn or defective parts.
2. Fit circlips in the two differential wheels.
3, Locate the wheels and pinions in the differential casing
and drive the differential pinion shaft in.
—_—<$_$_——
NOTE
As from transmission No. F 68929, a new differen-
tial casing and new differential wheels, retaining
rings and inner drivers have been introduced. The
new parts have a somewhat larger diameter and a
larger number of lands in the splined joint and are
thus not interchangeable with the old ones.
4. Refit the ring gear and tighten the bolts with a torque
of 25 Nm (18 ft.lb., 2.5 kpm).
Note that the two long screws also serve to lock the Oy)
differential pinion shaft axially. ayy,
5 ’ re a = UAL
5. Secure the ring gear bolts with retaining rings and then nit
press the bearings on if they have been removed. HN
6. Position the differential in its bearing seats and place win
spacers and shims at the outside of the bearings. Check in)
that the differential has no axial play and that the bear- ie
ings are not jammed. Use thumb pressure only when
fitting the spacer. )
If any part affecting the total width of the differential
assembly has been renewed, for instance a bearing, the
ring gear backlash must be checked. The backlash is
adjusted by changing the combination of spacers and
shims as described under ‘Pinion shaft and ring gear’’.
7. Refit the two bearing caps and tighten the screws with
a torque of 40 Nm (29 ft.lb., 4 kpm). Reassemble the
clutch housing and universal joints.
_ és ew
Page 425
INNER UNIVERSAL JOINT
GENERAL
The inner universal joint comprises a driver which is
borne up in the differential casing and splined to the dif-
ferential wheels, to which it is locked by means of an
elastic retaining ring located in a groove in the differen-
tial wheel. When the driver is to be removed or refitted,
the retaining ring springs out in its groove.
Externally, the drive shaft is carried in needle bearings.
When the car is in motion, the shaft is axially slidable
and also articulated. The universal joint is lubricated with
Saab Special Chassis Grease and is protected by a rubber
boot. Lubrication is only necessary after reconditioning
or if the universal joint has been removed for some other
reason.
Always use Saab Special Chassis Grease.
SS
S 626
INNER UNIVERSAL JOINT
MIDDLE SHAFT AND INNER
Disassembly universal joint
1. Jack up the front part of the car and remove the wheel.
2. Detach the brake housing, and hang it up by the wheel
house so that the brake hose will not get damaged. Re-
move the wheel hub and brake disc.
3. Remove the large clip holding the rubber boot in po-
sition.
4. Remove the upper ball joint from the steering arm
and the lower ball joint from the steering knuckle.
5. Open up the inner universal joint and fit a cover. tool
73 23 736 in the rubber boot to keep the needle bear-
ings in and dirt out. On the inner driver, fit protective
cover 78 38 469.
6. Withdraw the middle shaft together with the rubber
boot through the wheel house.
Febr 1977
REMOVAL AND INSTALLATION OF INNER DRIVE SHAFT
7. Next, possibly tap the driver off the transmission case,
using an arbor, and remove it.
8. If the rubber boot at the inner or outer universal joint
needs to be changed, separate the shaft from the outer
joint. See Outer universal joint”.
The rubber boots can then be removed from the shaft.
9. If the sleeve of the inner driver is worn, you may (with
a suitable tool) press off the sleeve from the driver,
and turn it 90° or, fit a new sleeve. Press until the
sleeve flushes with the end surface of the driver.
Reassembly
1. Thoroughly clean the inner driver and then pack the
needle bearing grooves with a soft, lithium-based EP
grease. The correct amount will be applied if the driver
is packed completely full with grease.
2. Refit the inner driver by sliding it into the transmis-
sion case.
Check that the retainer in the differential gear engages
correctly.
3. Pass the rubber boots onto the middle drive shaft and
fit the shaft and rubber boot to the outer universal
joint. See “Outer universal joint’’.
4. Apply Saab Special Chassis Grease to the needle bear-
ings and fit these to the shaft journals.
NOTE
As from transmission No. F 68929, a new differen-
tial casing and new differential wheels, retaining
rings and inner drivers have been introduced. The
new parts have a somewhat larger diameter and a
larger number of lands in the splined joint and are
thus not interchangeable with the old ones.
SAA 475—1
Page 426
eae eres ee Pe
ctiser Bove
Fit the cover 73 23 736 in the rubber boot to protect
the needle bearings and to prevent th
out. Then pass the shaft and rubb
the wheel house.
em from falling
er boot in through
Remove the cover from the rubber boot and pass the
shaft and needle bearings into the inner driver. Then
refit the rubber boot and the clips.
Refit the upper and lower ball
joints to the steering
knuckle,
Refit the brake disc and wheel hub, as well as the
brake housing and friction pads.
8. Refit the wheel.
REPLACEMENT OF SEALING RING
1. Detach the steering knuckle from the upper and lower
ball joints and hang it up to prevent damage to the
brake hose.
Drive the inner universal joint out of the transmission
case with the aid of an arbor, and pull the shaft out
without disassembling the inner universal joint.
Prise the sealing ring off with a screwdriver, making
sure that it is accompanied by its spring.
REMOVAL OF SEALING RING AROUND OUTPUT SHAFT
4. Drive a new sealing ring in, using arbors 78 40 333
and 78 40 309. The ring must be driven in 0.1 in. (2.5
mm) as shown in the figure in order to ensure sufficient
clearance.
2,5 mm
FITTING A NEW SEALING RING
1. Sealing ring
2. Arbor 78 40 333
3. Handle 78 40 309
5. Refit the universal joint to the transmission Case and
connect the ball joints to the steering knuckle.
IMPORTANT
Before refitting the universal joint, fill the space be-
tween the lips of the sealing ring with Saab Special
Chassis Grease. Take great care when reassembling
the universal joint, so that the splines do not dam-
age the seal.
REPLACEMENT OF BROKEN INNER DRIVER
If the pin for the inner driver has broken inside the trans-
mission case, a special tool can be used to remove it with-
Out any necessity of disass:
1. Remove the defective j
side, remove the midd}l
2. Using the driving arbo
broken pin with the s
it from the side oppo
embling the transmission unit.
nner driver. On the opposite
e shaft and outer universal joint.
178 41 422 first tap out the
hort part of the tool, inserting
site that where the broken pin
ae SOARE
Febr 1977
Page 427
is located. Then reverse the tool and tap the pin out
completely with the fork shaped part.
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$18
TAPPING OUT BROKEN INNER DRIVER
1. Driving out arbor 78 41 422
2. Shaft pin
3. Fit new parts.
OUTER UNIVERSAL JOINT
GENERAL
On the outer universal joints, the outer drive shaft is in
the form of a dome with spherical grooves, in which six
balls transmit the power from a hub. The middle drive
shaft and the hub are splined, and a retaining spring is
used to hold the shaft at the hub. When installing the
shaft, the retaining spring is compressed with a special
tool, and the shaft is then passed into the hub. A spe-
cial tool is also used to drive the shaft out of the hub in
disassembling.
The only spare parts available are the outer drive shaft,
complete with hub, ball holders and balls. These parts
are matched and must not be mixed up.
Lubrication is necessary only after reconditioning, or if
the universal joint has been removed for some other rea-
son. Saab Special Chassis Grease shall be used.
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OUTER UNIVERSAL JOINT
1. Wheel hub 4. Lock ring 7. Hub
2. Steering knuckle housing 5. Outer drive shaft 8. Rubber bellows
3. Ball bearing 6. Balls 9. Inner drive shaft
Febr 1977
475-3
Page 428
bearing out of the steering
passé jrive the
eS 8. If necessary, © r at
knuckle from the inside.
é from their seats in
Remove the two sealing rings
1. Jack up the front part of the car and take off the 9. whe eteoring knuckle nut if they require changing.
wheel. Remove the brake housing and hang it up by a che middle drive shaft in a vise and strike
: ¢ ©
the wheel house to prevent damage to the brake 10. Sect cesaatites alte
the hub off the sh
hose. Then remove the hub and the brake disc.
2. Remove the steering arm and upper ball joint from
the steering knuckle.
3. Back off the clamping screw which holds the lower
ball joint to the steering knuckle.
4. Remove the large clamp for the rubber boot on the
inner universal joint and open up the joint. Fit cov-
er 73 23 736 into the rubber boot to prevent the
needle bearings from dropping out and dirt from
entering the joint. See ‘Inner universal joint’’. Fit
protective cover 78 38 469 onto the inner driver.
5. Pull the drive shaft out through the wheel house
and remove the front axle assembly. Wash this as-
sembly thoroughly.
6. Remove the nut and shaft seal from the steering
knuckle. Use the pegged key 78 40 200. First prise
up the nut retainer with an arbor or other suitable
REMOVAL OF INNER DRIVE SHAFT FROM OUTER UNI-
VERSAL JOINT
Tool 78 42 024
tool.
7. Remove the outer drive shaft by applying pressure es
to its outer end. The outer drive shaft will be accom- NOTE
pained by the universal joint, rubber boot and mid- The hub, ball holder and balls can be removed from
dle drive shaft. the dome if the hub is turned 90° in a certain posi-
tion. Disassembly, however, should be carried out
only if absolutely essential.
PRESSING OUT THE OUTER DRIVE SHAFT
— Febr 1977
Page 429
REASSEMBLY
Clean all the component parts thoroughly, and replace
worn or damaged parts by new ones. Pay particular at-
tention to shaft seals and rubber boots.
1, Grease the outer universal joint using Saab Special
Chassis Grease. The correct quantity will be ob-
tained by packing the dome containing the hub
and bails full with grease. Take the utmost care in
preventing dirt from entering the joints and bear-
ings.
2. Slide the rubber bellows and clips onto the inter-
mediate drive shaft, Mount the rubber bellows on
the universal joint.
3. Mount a new circlip on the intermediate drive shaft
and compress by means of tool 78 41 612.
NOTE
The circlip ends should overlap under a jaw of the
| pliers. They will therefore not be clear of each other
when the pliers are closed.
=
PLACING THE LOCK RING IN TOOL 78 41 612
4. Insert the shaft in the hub and lightly tap the shaft
end so that the circlip clicks in. Remove the pliers
and fully insert the shaft in the hub.
Febr 1977
e $ 679
INSTALLATION OF INNER DRIVE SHAFT
Tool 78 41 612
5. If the seal in the steering knuckle housing has been
removed, insert a new one.
6. Pack the bal! bearing with Saab Special Chassis
Grease. Use only original ball bearings.
‘7. Press the bearing into the steering knuckle housing
with the numbered designation on the outer race
facing outwards. Use tool 78 40 754 and 78 40 309.
475-5
Page 430
; + > 3 A> 4-*->> >
ee
PRESSING IN THE BALL BEARING IN THE STEERING
KNUCKLE. THE MARK ON THE BALL BEARING FACING
OUTWARDS.
Tools 78 40 309 and 78 40 754
10.
Tighten the nut and shaft seal using hook wrench
78 40 200. Lock the nut.
Pack the space between the lips and the inner seal
with chassis grease.
Mount the outer drive shaft (with intermediate
drive shaft already mounted) in a press and press
on the steering knuckle housing and bearing. Use
sleeve 78 41 067 locating on the inner ring of the
bearing.
PRESSING THE KNU
THE OUTER DRIVE SHAFT
Tool 78 41 067
475-6
CKLE HOUSING AND BEARING ONTO
1T.
12,
13.
14.
15.
16.
Fit the two clamps on the outer rubber boot and
the clamp for the inner boot at the shaft.
If the needle bearings have been removed, lubricate
them with Saab Special Chassis Grease and mount
them on their journals. Fit cover 73 23 736 as pro-
tection for the needle bearings and pass the drive
shaft in through the wheel house. Make sure that
the inner driver is clean and that it has been packed
with Saab Special Chassis Grease, see ‘Inner univer-
sal joint”. Reassemble the inner universal joint and
tighten the clamp round the rubber boot.
Refit the steering knuckle to the steering arm and
lower ball joint. Remember to provide tabbed wash-
ers at the screws, and to secure these.
Refit the hub and the brake disc, followed by the
brake housing and friction pads. Secure the screws
with tabbed washers.
Refit the wheel and lower the car to the floor,
Tighten the axle nut to a torque of 180 Nm (130
ft.lb., 18 kpm), and secure.
Refit the hub cap.
CAUTION
The friction pads must be returned to their posi-
tions near the brake disc. To ensure correct posi-
tioning, pump repeatedly with the brake pedal.
Negligence in this respect will result in brake fail-
ure.
Febr 1977