Page 501
of the taper pin. Tighten the nut, thus loosening the
pin.
9, Release the universal joint from the gear shift shaft
collecting the gear lever return spring which is lpcated
on the gear shift shaft.
3, Remove the fastener and drive out the other taper pin
in the same way.
4, Pull the joint off the transmission Operating rod. Check
the joint for excessive play or stiffness. If new dust
excluders are to be fitted, remove the old grease and
pack the joints with Saab special chassis grease before
fitting the new dust excluders,
5, Refit the universal joint to the Operating rod and drive
in the taper pin. Make sure that the tapers in the joint
and operating rod are properly aligned.
NOTE
The gear shift rod joint on L.H.D. cars has the
links displaced. The color marked end of the joint
should be mounted against the gear box,
6, Refit the return spring to the gear shift shaft if it has
been removed. Then pass the universal joint onto the
shaft and drive in the taper pin.
7, Refit the taper pin fastener.
GEAR LEVER LOCK, IGNITION LOCK
General
The car is fitted with a combined ignition and gear lever
lock. The gear shift lever is locked when the reverse gear
is engaged and the key is removed. The gear lever and ig-
nition lock has the following positions:
oz S 28
GEAR LEVER AND IGNITION LOCK
Febr 1977
L. Locked. The lighting is out when the key is turned to
locked position. The key can be taken out only when
reverse gear is engaged,
» Garage, Ignition, etc., is switched off but the gear shift
lever is unlocked. The key cannot be removed in this
Position,
- Driving. Ignition is on, Current is supplied via the 19°
nition switch to the fuel tank gauge, direction indi-
cator flashers, fan motor, windshield wipers, horn and
charge indicator light.
S. Starting. This position has a spring return action.
The steering column stand is secured to a bracket under
the instrument panel by means of two screws. These
screws have waists and are locked with roll pins. They
can be slackened enough to allow adjustment of gear
Positions, but if the steering column stand is to be re-
moved, the roll pins must first be Knocked out with an
arbor.
The gear lever lock consists of a twist stop secured to the
gear shift shaft by means of two clamping screws, one
stop screw and knurls. The twist stop has a hole into
which the lock plunger slides when the gear shift lever
is locked,
NOTE
Readjustment of the twist stop for the lock plunger
is essential whenever the gear shift mechanism has
been dismantled and after adjustment of gear posi-
tions.
/ $
Lf
Lo 2
VA vas
$ 353
TWIST STOP AND LOCK PLUNGER
1. Steering column
2. Twist stop
3. Clamping screw
4. Gear shift shaft
5, Stop screw
6. Lock plunger
7. Lock cylinder with key
641-1)
wereeseersosocssesers
*2ESSsSSSsF=F=S2=F=F=F==
SSSSSSSSFSS=F=25S=5=2==
Page 502
Removal of twist stop
1. Engage 1st gear, thus providing access to two clamp-
ing screws On the twist stop through the holes (2) on
the bottom of the steering column stand. Undo these
internal hexagon screws with a 3/16” spanner.
2. Engage reverse gear and turn the ignition key to the
locked position (L), enabling the stop screw which
holds the twist stop to be backed off through the low-
er hole 2, in the steering column stand.
S 352
GEAR LEVER LOCK, CUT-AWAY VIEW
. Clamping screw
. Adjusting hole
. Twist stop
. Gear shift shaft
Steering column stand
. Gear shift lever
OOaAWN=
3, The gear positions can now be adjusted by moving
the steering column stand in the ordinary way. If the
ignition key is turned to position G, thereby releasing
the twist stop, the gear shift mechanism can then be
dismantled.
NOTE
The clamping screws of the twist stop are always
accessible when 1st gear is engaged and the stop
screws when reverse gear is engaged.
Adjustment of twist stop
After adjustment of gear positions, readjustment of the
twist s
1.
top is called for. The procedure is the following:
The twist stop is marked on the side that is to face up-
wards towards the steering wheel. The marking shows
for which version the twist stop is designed, e.g. V-4
means left hand drive, 4-speed.
Engage reverse gear and push the twist stop up. At the
same time, turn the ignition key to the locked posi-
tion (L) and check that the lock plunger finds its posi-
tion in the twist stop.
. The twist stop now hangs on the lock plunger. Move
the twist stop up about 0.08 in. (2 mm) and tighten
the stop screw slightly. Note! Do not tighten the screw
up too hard, its purpose being merely to hold the twist
stop during adjustment.
. Turn the ignition key to position G and engage Ist
gear, enabling two clamping screws on the twist stop
to be tightened. Then engage reverse gear and slacken
the stop screw. Return to 1st gear and tighten the
clamping screws permanently. Now engage reverse
gear again and tighten the stop screw enough to pre-
vent it from working loose.
ADJUSTMENT OF TWIST STOP
641—12
Note! On right hand drive cars there is a spring on the
gear shift shaft which serves as a reverse catch. This spring
must be in place when the twist stop is adjusted,
Febr 1977
Page 503
Lock CYLINDER, UP TO AND INCL. cHas
SIS
95773000341 AND 96773000960 NO,
wo no
!
$3576
LOCK CYLINDER AND GEAR LEVER LOCK
1, Catch pin
2. Lock cylinder
3. Sign plate
4. Gear lever lock
5. Lock plunger
6. Lock plug
7. Retaining washer
8. Cross-recess screw
9. Catch pin (as from model 1970)
Disassembly
1. Insert the ignition key and turn to right hand edge of
the "ASSA” mark.
POSITION OF KEY AND LOCK PLUNGER DURING ASSEM-
BLY OR DISASSEMBLY
1. Catch pin
2. Position of locking pin during assembly of lock cylinder
3. Gear lever lock
4. Sign plate
5. Position of key during assembly of lock cylinder
Nov 1977
2. When the key is in this position, the catch pin in the
lock cylinder can be pressed in by inserting a wire
Picklock in a hole on the underside of the steering
column stand. See figures.
0.1 in. (2,5 mm) 0.32 in. (8 mm)
R = 0,4 in. (10 mm) ©
WIRE PICKLOCK
$3575
REMOVING LOCK CYLINDER
1. Lock cylinder
2. Lock plug
3. Retaining screw
4. Catch pin (as from model 1970)
3. Pull out the lock cylinder and remove the lock plug
through the cylinder hole.
4. The gear lever lock can now be removed, after re-
moval of the retaining screw.
NOTE
When the lock cylinder is removed the key has no
stop positions and can thus be turned a complete
revolution. If the key takes up an incorrect position,
the locking pins inside the cylinder may get in the
way so that the key cannot be returned to the work-
ing position. To remedy this, tap the key and lock
cylinder lightly against a wooden object with the
retainer on the outside of the cylinder turned up-
wards.
a
641-13
Page 504
Disassembly when key is missing
If the key has been lost or if it is necessary to remove
the lock or the lock cylinder, the cylinder must be drilled
before the catch pin can be pressed in. Drill an 0.12 in.
(3 mm) hole in the cylinder to a depth of about 0.4 in.
(10 mm).
DRILLING LOCK CYLINDER FOR REMOVAL WHEN KEY
IS MISSING
1, Hole, diameter 0.12 in, (3 mm), depth 0.4 in. (10 mm)
Reassembly
1, Slide the lock plunger into the gear lever lock and then
fit the lock into the steering column stand.
2. Insert the screw and drive it in slightly. Insert the lock
plug.
3. Using flat nose pliers, turn the pin in the lock until it
enters the groove in the end of the lock cylinder, see
fig.
4. Turn the key so that it comes to the right hand part
of the ‘“ASSA” mark, and press the catch pin in.
5. Nov place the sign plate over the pin so that it is held
in the pressed-in position. Adjust the sign plate so
that it fits against the retaining lug on the outside of
the cylinder.
6. Insert the lock cylinder with the sign plate in the gear
lever lock and tighten the screw.
LOCK CYLINDER, AS FROM CHASSIS NO.
95773000542 AND 96773000961
Removal
1. Put the gear lever in reverse and turn the key to a pogj.
tion mid-way between position “L” and "GG".
POSITION OF KEY FOR REMOVAL AND INSTALLATION
OF LOCK CYLINDER
1. Cylinder ring
2. Key
2. Insert a wire picklock in the hole underneath the steer-
ing wheel bearing bracket and depress the lock cylinder
locking pin.
S 6167
REMOVING THE LOCK CYLINDER
1. Lock cylinder
2. Plug
3. Locking pin
3. Withdraw the lock cylinder,
641—14 SAAB
Nov 1977
Page 505
installation
1. Check that the driver is correctly
. Positioned in the
lock sleeve. Adjust as necessary u
sing flat-nose Pliers,
— Pm
S 6168
|
POSITION OF DRIVER FOR INSTALLATION OF CYLINDER
1. Hole for locking pin
2. Driver
2. Insert the cylinder in the lock sleeve. Insert the locking
pin.
641—15
Page 507
STEERING GEAR
General
To lubricate the steering gear, turn the steerin h
far as it goes to the left, to the right on R.H De Pie
Saab special chassis grease. ee
To ensure satisfactory function, the steering gear
iybricated copiously, but not so excessively that ae
Udematoot bellows are completely filled with grease.
henbicons Oise in the steering gear is a sign that adjust-
essary, see below. Worn or damaged parts
should be replaced by new ones.
wee shows a steering gear for a car with left
hand iii | ue os the steering gear for cars with right
: is similar in principle, the following instruc-
tions are equally applicable to both versions.
STEERING GEAR, L.H.D. CAR, DISASSEMBLED S 4204
A. Alternative design
1. Steering gear housing
2. Rack
3. Bushing
4, Spacer sleeve
5. Pinion
6. Washer
7. Shim
8. Bearing
9, Piston
10. Spring
11. Screw
12. Nut
13. Cotter pin
14. Shim
15. Nut
16. Flat spring
17. Bearing cup, inner
18. Bearing cup, outer an
19. Tie-rod ;
20. Nut
21. Tie-rod end
22. Rubber bellows
23. Locking pin
24. Spring
SAOES 642—1
Febr 1977
i —
————————— ae
Page 508
REMOVAL, UP TO AND INCL. MODEL 1968 (R.H.D.
CARS UP TO AND INCL. MODEL 1969)
The following description is applicable on left hand drive
cars and right hand drive cars as well. (Text in brackets
is applicable on right hand drive cars.)
1.
2.
3.
Remove the hood.
Disconnect one of the battery cables.
Jack up the front part of the car so that both wheels
are clear of the floor.
Take off the front wheels.
Disconnect the tie-rod ends from the steering arms.
Use tool 78 60 448 for the tie-rod end.
a —st “
REMOVAL OF TIE-ROD END
Tool 78 60 448
bd
10.
11.
12.
13.
14,
642-2
Back off the nut and remove the tie-rod end from
the left tie-rod on a L.H.D. car (on a R.H.D. car the
right).
Remove the lower tapper pin from the gear shift
shaft universal joint. Remove the nut and place it
on the other end of the taper pin. Tighten the nut,
thus loosening the pin. Release the joint from the
gear box.
Release the freewheel control from the transmission.
Detach the slave cylinder from the clutch housing
and hang it up on the hoses for the fresh-air heater.
Release the throttle return spring and attach it in
some suitable way so that the throttle spindle is
fully deflected.
Disconnect the speedometer drive cable from the
transmission case.
Turn the steering wheel to full left lock on a L.H.D.
car (and full right lock on a R.H.D. car). Back off
and remove the clamping screw in the steering co-
lumn yoke and lift the steering wheel to pull the
column out of the yoke. Remove the dash panel
cardboard lining where the steering gear stub passes
through the dash panel.
Back off and remove the four steering gear retaining
bolts.
Remove the rubber grommet in the dash panel. Lift
the left hand (resp. right hand on R.H.D. cars) side
of the steering gear forwards over the gear shift fork
shaft until the stub axle on the steering gear is clear
of the dash panel.
15.
Pass the steering gear out a little through the right
hand (resp. left hand) wheel house until the left
tie-rod clears the wheel house wall. Lift the steering
gear out forwards and upwards between the wheel
house stay and the left hand wheel house.
REMOVAL OF STEERING GEAR
INSTALLATION, UP TO AND INCL. MODEL 1968
(R.H.D. CARS UP TO AND INCL. MODEL 1969)
ne
12.
13,
14,
15,
O29 9M
Remove the tie-rod end from the left hand tie-rod
(right hand on a R.H.D. car).
Slide the rack over so that left hand (resp. right
hand) tie-rod takes up its inner position.
Insert the steering gear between the left hand, (resp.
right hand) wheel house and the wheel house stay
in the opposite way to removal.
Pass the steering gear in towards the dash panel in
the opposite way to removal and place the rubber
seal on the stub axle to avoid damaging it.
Pass the stub axle through the dash panel and refit
the rubber seal in the dash panel hole.
Refit the four retaining bolts in the steering gear.
Before tightening these bolts, make sure that the
speedometer drive cable is not caught between the
steering gear and the dash panel.
Refit the left hand (resp. right hand) tie-rod end.
Reconnect the tie-rod ends to the steering arms.
Put on the wheels and lower the car to the floor.
Refit the freewheel contro! and gear shift shaft uni-
versal joint,
Reconnect the speedometer drive cable to the trans-
mission case.
Refit the slave cylinder to the clutch housing.
Reconnect the throttle return spring.
— the wheels Straight ahead, refit the cardboard
8" panel lining and reconnect the steering column.
Check the toe-in and ti '
tighte .
rod ends. ghten the lock nuts at the ti
Febr 1977
Page 509
Check the alignment of the steering whe
the clamping screw in the yoke on the s
jumn.
17, If necessary, grease the tie-rod ends,
8. Reconnect the battery cable.
19. Refit the engine hood,
el and refit
teering co.
EMOVAL, AS FROM MODEL 1969 (R.H.D. CARS As
FROM MODEL 1972) :
As from model 1968, there is an alternative
featuring 2 different inner ball joint. As fro
1969, only the new type is used,
As from model 1969, the brake system is equipped with
yacuum servo (on R.H.D. cars as from model 1970),
The placement of the servo cylinder has made necessary
another way of removal and installation of the steering
gear.
The following description is applicable on left hand drive
cars and right hand drive cars as well. (Text in brackets
is applicable on right hand drive cars.)
1. Remove the hood.
2. Disconnect one of the battery cables,
3. Jack up the front part of the car so that both wheels
are clear of the floor,
4. Take off the front wheels.
5, Remove the tie rod ends from the steering arms.
Use tool 78 60 448.
steering gear
mM model
REMOVAL OF TIE-ROD END
Tool 78 60 448
6. Remove the lower taper pin from the gear anit
shaft universal joint as follows: Remove the nut
and place it on the other end of the taper pin.
Tighten the nut, thus loosening the pin. Release
the freewheel control from the transmission.
7. Release the throttle contro! spring. The spring a ‘
then be used as a support for the gear si ae h
joint. Disconnect the speedometer cable fon
transmission case. 2 in the
8. Back off and remove the clamping screw x heel
steering column yoke and lift the steering ee a
to pull the column out of the yoke: 2 ie stand
the screws for support of the steering co i moved
must be backed off so that the stand can
to its upper position.
Febr 1977
WARNING
The collapsible steering wheel shaft introduced as
from model 1969 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
9,
Back off the lock nut on the underside of the steer-
ing gear. Use ring spanner 1 1/4”. Remove the screw
with the aid of spanner 11/16’. Note! The screw is
not hexagon, it has only one key grip. Remove the
pressure spring and the piston.
PRESSURE SPRING AND PISTON REMOVED
10. Remove the screws holding the pinion bearing. Re-
move the bearing. Take care of the shims. Pull out
the pinion.
11. Back off and remove the four steering gear fastening
screws.
12. Pass the steering gear out through the left hand
wheel housing (resp. right hand on R.H.D. cars),
Avoid damage on the rubber bellows.
Check and adjust, see instructions on page 642—5
and following pages.
INSTALLATION, AS FROM MODEL 1969 (R.H.D.
CARS AS FROM MODEL 1970)
If a new steering gear is installed, the steering gear pinion
must first be removed, see pos. 9 above.
1. Pass the steering gear in through the left hand whee!
housing (right hand on R.H.D, cars). For making it
possible to pass the gear by the gear shift shaft the
gear must be turned so that its mounting heads
comes in the best possible position. Do not damage
the rubber bellows.
2. Mount the steering gear to the dash panel.
3. _ Install the steering gear. Use same shims as used
when checking. Check that the pinion moves easily.
642-3
Page 510
i te
Mount piston, spring and screw for adjustment of
the radial play of the rack. Tighten the screw so
that smallest possible play is obtained without
jamming the rack, Tighten the lock nut.
6, Remove the pinion.
7. Disassemble the ball joints and collect the shims, the
inner ball seats and the retainer.
8. Withdraw the rack from the steering gear housing.
5, Fit the tie-rod ends to the steering arms. Tighten 9, Remove the pinion spacer. If they are to be renewed,
the nuts and lock them with cotter pins. drive out the pinion bushing and the bushing on the
6. Fit the wheels. Align the wheels straight ahead. Fit R.H. side of the steering gear.
the steering wheel shaft to the pinion.
WARNING
The collapsible steering wheel shaft introduced as
from model 1969 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 shockabsorbing
effect.
When installing the steering wheel shaft, take spe-
cial care to ensure that the splined lower end is
pushed into the intermediate shaft until the clamp-
ing screws comes opposite the groove in the shaft.
The intermediate shaft should normally slide freely
on the shaft. If the splines stick, do not on any ac-
count knock on the top end of the steering wheel
shaft.
This also applies to removing and fitting the steer-
ing wheel. The wheel must not be knocked off or
on.
The last mentioned bushing may be found locked with
a pin.
REASSEMBLY, EARLIER DESIGN
The steering gear must be reassembled under conditions
of scrupulous cleanliness. Lubricate the rack and pinion,
bearing points and other sliding surfaces with Saab special
chassis grease.
1. If removed, drive the pinion bushing into the steer-
ing gear housing.
2. Place a new retaining washer on the pinion end of
the rack and screw on the nut with tool 78 40 713.
3. Locate the shims on the nut and place the inner
ball seat and retainer inside the nut. Position the
retainer with its concave side facing the ball seat.
4. Pass the rack and pinion into the steering gear
housing,
NOTE
In assembling the steering gear, the pinion spacer
must be refitted before the rack is passed into the
7. Install the gear shift shaft joint. Tighten the screws housing.
for the steering column stand if this has been loose-
ned. Check the gear positions.
8. Mount the freewheel control and throttle control 5. Pass the outer seat onto the tie-rod and secure it to
spring. the nut with the aid of the special tool, 78 40 713.
9. Lower the front of the car and check toe-in. 6. Check that the ball joint is correctly shimmed., If
10. Connect the battery cable. Mount the engine hood. not, release the ball seat and alter the shim combi-
DISASSEMBLY, EARLIER DESIGN
PWN
. Back off and remove the lock nuts and remove the tie-
rod ends.
. Release the clamps and take off the rubber bellows.
Bend up the tabs on the retaining washers.
If the gear pinion has been removed, put it back in
place.
Release the two tie-rod ball joints with tool 78 40 713.
If the nut is left on the rack, it can be removed using
the shaft of wrench 78 40 713.
$783
nation as indicated below under ’’Adjustment”.
7. After proper adjustment of the ball joint, bend the
tabs of the retaining washers down into the grooves
on the outer ball seat and into the notches in the
nut.
SECURING INNER BALL JOINT
REMOVAL AND FITTING OF NUT
Tool 78 40 713
Febr 1977
642-4