Page 541
GENERAL
the car has a body of unit construction. Fenders, doors,
and luggage compartment lid are removable, The
is composed of a relatively small number of pressed
ste! parts which are joined together by spot welded or
tackwelded overlapping seams. In addition, all vital june-
tions are solid welded.
The Saab 95 differs from the Saab 96 in that the rear end
and the roof are different.
The roof panel is a single pressed steel part, extending
from the dash panel to the leading edge of the luggage
compartment lid. Pressed reinforcement frames are fitted
round the windshield and rear window. Tubular reinfor-
cement is provided in the windshield pillars, while steel-
section roof rails add rigidity to the sides of the roof.
The cowl section of the roof panel terminates in front of
the windshield with a vertical reinforcement panel which,
together with the dash panel and the windshield reinfor-
cement frame, forms a closed compartment. The space
thus enclosed serves as a collecting chamber for ventila-
tion air, which flows in through the opening in the upper
side of the chamber and which can be admitted to the car
either through a flap on the right hand side of the dash
panel or through the fresh-air heater.
The floor consists of a single smooth panel, with longi-
tudinal channels affording the necessary stiffening. At the
sides, rigidity is provided by the sills, to which the jack
supports are welded. At the front, the center floor adjoins
the dash panel, and at the rear the rear axle tunnel. The
engine compartment floor pan is joined to the center
floor at the dash panel, and the luggage compartment
floor pan behind the rear axle tunnel.
The wheel house walls are of pressed steel, channeled for
reinforcement, The two front wheel houses are pierced
for the control arms and tie-rods, as well as to allow eva-
cuation of the current of air passing through the radiator.
Some of the air outlets are fitted with gills. The brackets
for the front control arms are welded to the inside of the
wheel house walls and to the engine compartment floor.
One of the rear wheel house walls is pierced for the fuel
filler pipe, the other being fitted with a bracket for fitting
the rear muffler. The upper spring seats and shock absorb-
er brackets are welded to the wheel houses at both front
and rear.
The luggage compartment of the Saab 96 comprises the
rear most part of the body and is limited at the front end
by the removable back cushion of the rear seat. The com-
partment floor consists of a sheet of plywood, divided in-
10 two parts, under which the fuel tank and spare wheel
fe housed. The luggage compartment lid is carried on
oo and fitted with a counterbalanced check de-
nood
pody
BODY INSULATION
Passenger and rear compartments are internally insulated
with waffle pattern paperboard.
A layer of insulation compound has also been sprayed on
the underside of the body assembly and inside the wheel
houses. This compound affords protection against flying
stones and corrosion, besides having certain sound absorb-
ing properties. When cleaning the car, never scrape the in-
side of the wheel houses.
BODY FITMENTS
The interior fitments of the car comprise chairs and seats
and door and side linings retained by quick-release spring
clips, headlining and mats.
The headlining in the Saab 95 is stretched on pianowire
bows and retained by wire spirals in the roof rails. Because
of the simplicity of the retaining devices, all parts are easy
to remove. Saab 96 is equipped with a headlining that is
wrapped round the upper edges of the frames for the wind-
shield-, side- and rear window frames fastened with tape
carrying adhesive on both sides.
The door linings are retained with quick-release spring
clips at the lower and rear edges. At the leading edge, the
trimming is secured by a U-shaped bar, while at the upper
edge there is a protective strip, also secured with quick-
release springs.
Page 543
BODY ASSEMBLY
GENERAL
Any parts of the body assembly that have been so seri-
ously damaged as the result of a collision or other acci-
2. Windshield frame
3. Front wheelhouse
4. Sill
5. Rear wheel house
6. Front floor
dent that correction by beating or realigning is not suit-
able should be replaced by new ones. In many cases, even
minor damage may be more quickly and cheaply repaired,
and with better results, if the affected parts are replaced
rather than repaired,
BODY ASSEMBLY COMPONENTS AVAILABLE AS SPARE PARTS
1. Roof sheet, water channel
7. Rear pillar
8. Floor sheet, rear floor
9. Rear part
10. External valance, lower
11. External valance, complete
12. Front sheet
C—7.¥.. =} 810—1
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Page 544
ALIGNMENT JIG FOR ACCIDENT DAMAGED BODIES
An alignment jig with trueing-up tools and accessories to
fit both Saab 95/96 and Saab 99 cars has been designed
to facilitate the repair of car bodies damaged in road ac-
cidents. There are two types of aligning jigs, one earlier
version and one later and more up-to-date version.
Alignment jig, earlier version
The alignment jig consists of a rigidly constructed frame
with plane surfaces containing a series of precision drilled
holes, Fixtures for accurate location of body parts can be
screwed into these holes. Special checking fixtures are
also provided; these are placed on top of the locating fix-
tures. When the car is set up On the alignment jig, it is
possible with the help of the checking fixtures to measure
any deformation of the chassis attachment points with-
Out having to remove parts of the chassis.
The alignment jig is provided with a pair of wheels to
make it mobile. It need not be secured to the floor, but
when in use it should be placed on a level surface with
the wheels removed.
ALIGNMENT JIG, EARLIER VERSION
SAA
810-2
Draw aligner, earlier version
The draw aligner is used to straighten out ic pa
portions of the car body. It consists of a lever : ic ‘
secured at the bottom by a chain to two of es egs 0
the alignment jig. A hydraulic pressure cylin he at-
tached to the middle of the lever, and a draw chain is at-
tached to the top. This arrangement makes the tool com-
pact and easily portable, and also allows the direction of
pull to be varied within very wide limits. The draw
aligner doesn’t need to be anchored to the floor.
Before the trueing-up tool is used it is mounted on the
alignment jig in the following manner:
DRAW ALIGNER, EARLIER VERSION
1. Draw chain
. Anchor chain
. Pressure cylinder
Lever
Pressure beam
. Hand pump
AAS wn
1, Select the desired direction of pull, first laterally by
positioning the draw aligner accordingly, and then
vertically by attaching the draw chain at a suitable
height on the lever.
2. Secure the draw aligner to the alignment jig by
fastening both ends of the anchor chain to two of the
legs of the jig in such a way that tension will be ap-
plied to both halves of the chain.
3. Place the pressure cylinder against the pressure beam
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-
Febr 1977
Page 545
tended, will intersect at the same point on the floor
or will be almost parallel.
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.
Application of draw aligner, earlier version, principle
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
ih then no free forces tending to lift the tool or the
alignment jig.
—SSS ee eee
—s
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a
——=
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——— a ann
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$4212
APPLICATION OF DRAW ALIGNER
Hoisting gear, etc. for alignment jig, earlier version
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 con-
sisting 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 tresh-
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 posi-
tion with the jack.
A suitable bench or platform about 1 1/2—2 ft. (450—
600 mm) high should be available for work on the roof
of the car or upper parts of the body.
810-3
Page 546
can be secured at any point round
secured to the jig by means ofa
tmost im-
d on castors and
tis
locking pin. It is of the u
be locked securely during opera-
Alignment jig, later version mounte
the frame of the jig. |
The alignment jig of the later version has the same clamp forked bracket and 2
sets as the earlier jig, but is lower, providing a more favor- portance that mle Syraye
able working height and simplifying mounting. The draw tion of the draw aligner.
aligner is secured directly to the jig, which makes it easier
to work with.
The jig is mounted on four castors and is designed to stand
on these even during the aligning work.
aur
ALIGNMENT JIG, LATER VERSION
Draw aligner, later version
The Caroliner draw aligner, in a version designed specially
for this alignment jig, is equipped with a hydraulic cylind-
er which can apply a load of ten tons. The draw aligner is
seeabas se A le IN AN UPWARD DIRECTION BY
tONAL HYDR
Anica olaie AULIC CYLINDER AND
DRAW ALIGNER, LATER VERSION
810—4 SAAB
Febr 1977
Page 547
quipment, later design
E
EXTENSION PIECE MOUNTED TO DRAW-ALIGNER ARM
FOR THE APPLICATION OF LOADS AT ROOF HEIGHT
ALIGNMENT JIG WITH EQUIPMENT
1. Alignment jig, later design
2. Wheels
3. Side support
4, Draw aligner
SIDE MOUNTING FOR USE WITH A 4-TON HYDRAULIC & Eximnsion
CYLINDER 6. Support set, Saab 99 {also for alignment jig of earlier design)
7. Support set, Saab 95 L, 96 L (also for alignment jig of earlier
design)
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hs MOUNTING USED FOR APPLICATION OF DOWNWARD
D
810-5
SAAB
Febr 1977
Page 548
' ipti i ent jig and draw aligner
Mounting the car in the jig Description of alignm jig
A description of the alignment jig and accessories and
draw aligner is available and can be ordered from Saab-
Scania in Nykoping under the ordering number 101733.
The simplest method of mounting the car in the jig is to
use a side car lifting ramp with one or two pillars.
MOUNTING THE CAR IN THE JIG
The car can also be mounted in the jig by hoising it onto
high trestles by means of a high-lift jack, and then rolling
the jig in under the car. A side lifting ramp should then
be used to lift the car onto the jig mountings.
LIFT WITH TRESTLES AND JACK
810-6 SVB
Febr 1977
Page 549
CHECKING BODY DIMENSIONS
if any part of the body has had to be renewed or trai
ened, it is important to check the measurements oF te
e
door open
sion ici and the attachment points of the suspen-
be made 2 Wer unit. Diagonal measurements should also
check that there is no residual skew or asym-
metry after repairs.
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VIEW B-B
VIEW D—D
$ 1484
BASIC BODY MEASUREMENTS, SAAB 95
S$ 1487
— jt
810-7
Page 550
Body measurements, Saab 95
item in,
——
mm
Remarks
84.17 +0.08
13.66 +0.04
1.50 +0.02
3.33 + 0.06
8.27 £0.04
3.90 + 0.02
9.82 +0.06
3.94 +0.02
19.09 + 0.06
10 90.31 +0.12
11 30.87 +0.12
12 28.74 + 0.08
13 12.87 +0.12
OMONOUDAWN OC
14 14.37 0.12
15 §.47 £0.12
16 9.33 +0.04
17 2.09 +0.12
18 1.18 0.02
19 52.95 +0.16
20 6,34 +0.16
21 27.80 +0.12
22 41.34 +0.12
23 | 47.52+40.16
24 | 40.28+0.16
25 | 90°
26 | 54.21 +0.20
27 49.45 +0.12
28 16.54 +0.08
29 0.98 + 0.08
30 42.68 +0.08
31 28.74 + 0.08
33 10.67 +0.12
34 29.92 +0.08
35 25.31 +0.12
36 26.10 + 0.08
37 39.61 +0.12
38 59.21 +0.16
39 26.24 +0.08
40 17.71 £0.04
2138 +2
347 +1
38+0.5
84.5+1.5
210 +1
99 +0.5
249.5 41.5
100 +0.5
485 +1.5
2294+3
78443
730 +2
327 +3
36543
13943
237 +1
30 +0.5
1345 +4
16144
706 +3
1050 +3
1207 +4
1023 +4
90°
1377 +5
125643
420 +2
25+2
1084 +2
730 +2
271 +3
760 +2
643 +3
663 +2
1006 +3
150444
666.5 +2
450 +1
Underside of sill
To leading edge of pil-
lar reinforcement tube
To middle of center
bearing
To middle of center
bearing
To leading edge of pil-
lar reinforcement tube’
Tongue of dash panel,
elev. A and plan C—C
Measured parallel to
wheelhouse. See C—C
See elev. A and plan
C—C and plan G—G
See plan C—C and
H-H
To upper edge of pil-
lar
Holes for engine sus-
pension pads
810-8
VIEW H—-H
a =
2. | en,
ii
fil Se
a O os
ie
=
hae. 27 26
VIEW C-—C
|
S 1485
q
VIEW E-E
VIEW F—F
$ en
Febr 1977