Page 561
—e ===
\ \ S 969
OUTER HANDLE, UP TO AND INCL. MODEL 1971
6. Sleeve
m
y in 7. Push button
3, Washer 8. Catch pin
4. Washer 9. Lock cylinder
5, Spring
1. As from model 1972:
Remove the screw holding the push button arm (1)
and pull out push button (8) and spring (5).
OUTER HANDLE, AS FROM MODEL 1972 UP TO AND INCL.
CHASSIS NO. 95773000541 AND 96773000960
1. Arm 6. Sleeve
2. Washer 7. Sealing ring
3. Screw 8. Push button
4. Handle 9. Lock cylinder
5. Spring
2. Press the push button out of the sleeve (6).
3. Insert the key and turn it 35° to the right.
4. Press the catch pin (8) in with a driver (max. 0.12 in./
3mm),
5. Pull the lock cylinder (9) out of the push button.
If the key has been lost, the catch pin can be driven
into the lock cylinder by force, using a driver or pin
(with a diameter of max. 0.12 in/3 mm), thus en-
abling the cylinder to be removed from the push but-
ton. This treatment ruins the lock cylinder and a new
One must therefore be fitted,
Disassembly, as from chassis Nos. 95773000542 and
96773000961
1. Remove lock washer (1) securing push button (6) to
the handle (3).
2. Now remove the push button with the lock cylinder
(6).
The push button and lock cylinder form an integral unit
and must not be taken apart.
OUTSIDE DOOR HANDLE, AS FROM CHASSIS NOS.
95773000542 AND 96773000961
1. Lock washer 4. Ring
2. Driver 5. Spring
3. Handle 6. Push button and lock cylinder assembly
Reassembly, up to and incl. chassis No. 95773000541
and 96773000960
1. Drive in the catch pin and press the lock cylinder into
the push button.
2. Ease the sleeve onto the push button and then fit the
push button, together with the spring, in the handle.
3. a. Up to and incl. model 1971:
Insert the arm and the washers and drive in the pin.
Note that the two washers have different sizes of
holes,
b. As from model 1972:
Install the push button arm.
WARNING
Up to and incl. model 1971:
Do not press out the pivot that holds driver. The
pivot is guided by two spring loaded balls and can
not be refitted unless a special tool is used.
Assembly, as from chassis Nos. 95773000542 and
96773000961
1. Insert the push button with lock cylinder and spring
in the door handle.
2. Slide on the driver (2) and press on a new lock washer
(1) using a suitable sleeve.
Nov 1977 SAAB 830~3
Page 562
Spare parts
If a lock cylinder for a door, luggage compartment or ig-
nition lock is damaged, a new lock cylinder can be or-
dered, in which case the key number and spare part numb-
er must be quoted. See Spare Parts Catalogue. The sys-
tem whereby only one key is used for all the car locks
can thus be retained without any necessity of replacing
a complete lock kit.
Lubrication
If the lock cylinder is lubricated with oil or grease, the
lock pins may get caught in the cylinder. The reason for
this is that dirt adheres to the key and thus gets into the
lock cylinder. Because of this, the lock cylinder itself
should never be lubricated.
If the key moves stiffly in the lock, so that lubrication is
called for, a little glycerine may be applied to the back of
the key. NOTE! Never lubricate the indented side of the
key. After lubricating in this way, turn the key back and
forth a few times,
REAR DOOR, SAAB 95
Removal and installation
—
. Open the door.
2. Remove the sealing strip between door and body by
loosening and removing the self tapping screws in the
upper edge of the door.
3. Remove the retaining screw in each hinge which are
accessible when the door is open.
4. Remove the lever of the door lift from the gate by
removing the nuts, Be careful when removing the
lever as it is spring loaded.
5. Close the door.
6. Remove the attachment screws of the remaining
hinges.
7. Remove the door,
8. Installation is made in the opposite way.
Adjustment of balance spring tension
The rear door on the Saab 95 is fitted with two balance
springs, the tension of which can be adjusted with a nut,
The spring, which is accessible after removal of the trim
between the rear door and the quarter window, should
be tightened hard enough for the door to stop in any
position after opening.
ADJUSTMENT OF REAR DOOR BALANCE SPRING TENSION
Door lock
Replacement
1. Remove the inner handle by removing the plastic
shield and the lock pin. Note the spacer sleeve inside
the spring.
. Pry off the door lining.
3. Back off the lock nuts on the rods to the door locks.
(Note that the outer rods are left handed.) Remove
N
the adjusting nuts,
4, Remove the door lock retaining screws and lift out the
locks.
LOCKING DEVICE, REAR DOOR
1, Locking plate
2. Door lock
3, Switch rod, adjustable
830—4 SAAB
4. Inner handle (up to and incl. model 1
5. Latch sain
6. Outside handie
Nov 1977
Page 563
5, Fit new door locks and put the rods loosely togethe
7 r
h the adjusting nuts. , :
ne the i at the rod ° Remove the two retaining screws and hook the
6, Adjust g ro . © that the two door Spring off the clamp, whereupon the latch can be
locks are in the outmost position when the control removed,
handle is standing horizontally. Tighten the lock nuts. 7. Put the new latch in place with the serrated nut
threaded on as far as possible. The latch should be
turned, so that the joint for the right hand side
2 door lock rod is facing the bottom of the door.
5 Hook On the spring and install the nut on the out-
side of the door.
9. Fit the two retaining screws and tighten the serrated
nut.
10. Fit the adjusting nuts on the rods, Turn the latch
with the aid of the outer handle to separate the
ends of the rods so that the adjusting nuts can be
mounted.
11-
12. Adjust rods and door according to positions 6—7
Changing door lock”’.
Replacement of lock cylinder, up to and incl, chassis No.
95773000541
1. Fit the key and turn it 35° clockwise.
2.
ADJUSTMENT OF RODS, DOOR LOCK
7. Check the flush fit of the door. Adjust the striker
plates if necessary. Lubricate door lock and controls.
Refit handle and door trim.
Changing the latch
1-3. See position 1—3 ‘Changing door lock’’, Pull out
the outer handle.
—_ ——
7 4. Back off the serrated nut inside the door with the
aid of polygrip pliers.
5. Remove the chromium plated nut on the outside
of the door by placing mandrels in the two recesses
and turn with a screwdriver.
REMOVING THE NUT
Nov 1977
Push in the catch pin with the aid of a mandrel or
the like and pull out the lock cylinder,
REMOVAL OF LOCK CYLINDER
Push in the catch pin on the new lock cylinder.
Note that this can be done only when the key is
turned 35° clockwise. Engage the lock cylinder
in the handle and check that the catch pin gets
locking position.
830—5
Page 564
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SS Sewer
Replacement of lock cylinder, as from chassis No,
95773000542
Remove the door trim.
. Remove the split pin in the outside door handle (4).
. Withdraw the outside handle (4) and insert the key.
Knock out the tubular pin (3) using a 2.5 mm drift.
- Turn the key clockwise and carefully withdraw the
lock cylinder (2), ensuring that the locking pin (1) is
not lost,
ORWON=
N.B.
Never withdraw the key unless the lock cylinder is
in position in the handle, as the tumblers will other-
wise fall out.
LOCK, REAR DOOR, SAAB 95
1. Locking pin
2. Lock cylinder
3. Tubular pin
4. Handle
Fitting is carried out in the reverse order. Position the
locking pin so that the recess in the pin mates with the
driver on the lock cylinder.
830-6
TRUNK LID, SAAB 96
Removal and replacement
1. Raise the trunk lid and detach the stay. .
2. Disconnect the wires to the number plate lights and
trunk lamp. =
3. Back off and remove the hinge retaining screws On
the lid and lift off the lid.
NOTE
Take care to avoid damaging the body paintwork
when removing and replacing the trunk lid.
4. Replace the lid, proceeding in the reverse order.
Lock mechanism
Replacement
1. Unscrew the four retaining screws and remove the me-
chanism.
2. Install a new mechanism.
3. Adjust the flush fit of the trunk lid by moving the
yoke up or down.
LOCK MECHANISM
Nov 1977
Page 565
mbly, up to and incl. chassis No. 96773000960
he four retaining screws and remove the lock
pisasse
7,Unscrew t
mechanism.
Back off the two cross recess head screws holding the
lock mechanism installation washer, (The screws are
accessible through holes from the luggage compart-
ment.) Turn the washer so that the lock can be re-
moved.
Make a wire picklock (1) to the dimensions shown in
the fig.
Remove the retaining ring (2).
Remove the housing (3) and the torsion spring (4).
Turn the key 35° to the right.
Pass the picklock in towards the locking pin (7), turn-
ning to force the latter in towards the cylinder.
g, Withdraw the cylinder (6) from the lock.
Epistle cin
Assembly, UP to and incl. chassis No. 96773000960
1. Press the locking pin (7) into the lock cylinder (6)
and insert the cylinder in the sleeve (5). Note! This
can be done only when the key has been turned 35°
to the right.
2. Refit the torsion spring (4) and the housing (3), mak-
ing sure that the spring is inserted in the smallest of
the notches in the sleeve and in the hole in the hous-
ing.
3, Refit and press together the lock ring (2).
4, Install lock and lock mechanism in the car.
1. Wire picklock 5, Sleeve
2. Retaining ring
3, Housing
4. Spring
7. Catch pin
TRUNK LID LOCK, UP TO AND IN
6, Lock cylinder
Dj
—esembly. as from chassis No. 96773000961
* “nscrew the locking mechanism and luggage compart-
ment lock from the lid,
R ee
we the circlip (1) and carefully withdraw the
0b and lock cylinder assembly (5), taking care not
bf lose the two balls (2),
@ push button and lock cylinder form an integral unit
and must not be taken apart.
Assembly, as from chassis No. 96773000961
1. Insert the knob and lock cylinder assembly and the
spring (4) in sleeve (3) and fit the circlip (1).
2. Fit the lock and locking mechanism.
TRUNK LID LOCK, AS FROM CHASSIS NO. 96773000961
1. Retaining ring 4. Spring
2. Ratchet balls (two of) 5. Lock cylinder assembly
3. Sleeve
CL. CHASSIS NO. 96773000960
830-7
Page 566
GLASS
GENERAL
The windshield is made of laminated glass and all other
windows of toughened glass. When fitting new windows
use only Saab original parts to ensure approved Slane ‘
quality and a perfect fit.
WINDSHIELD
Replacement
1. Remove the windshield wiper arms, INSTALLATION OF WINDSHIELD
9, Press the windshield outwards with the hand from
inside the car, after having removed the rubber
weather strip from the bodywork.
9. Check that the inside flange of the weather strip is
inside the edge of the bodywork all round the
windshield, Cars with plastic windshield molding:
Moisten the weather strip with soapy water and fit
the molding, using tool 82 91 023. Fit the joint
pieces,
REMOVAL OF WINDSHIELD
3. Clean the contact surface of the weather strip on
the body, and remove all traces of old sealing com-
pound.
4, Fit a new weather strip to the windshield. Be sure INSTALLATION OF WEATHER STRIP
to locate the weather strip joint (possibly marked Tool 82 91 023
with a yellow dot) in the middle of the lower
edge of the windshield.
5. Cars with chromium plated molding: Press the trim =e rh ttwenc thai
moldin into i ing the thumb, and 10. Inject sealin er
fit o Pg eat ci strip and the body and between the weather strip
i
: : he glass.
6. i it i her strip. andt :
es a cord in the slit in the rubber ns oe ne 11. Remove excess sealing compound from the body
anne ne son ate tink . and glass, using kerosene or a similar solvent, and
per edge of the windshield. rinse thoroughly with water afterwards.
7. Coat the body opening and the weather strip
soapy water and put the windshield in position.
The lower edge of the bodywork shall enter the
groove in the weather strip.
8. From inside the car, pull the cord so that the edge
of the weather strip is drawn over the edge of the
penelling. Pull left and rightsides alternately while
an assistant presses the glass from the outside and
successively, with great care, pounds the rubber
weather strip with a rubber mallet.
with
843-1
Febr 1977
Page 567
REAR WINDOW AND SIDE WINDOWS
Replacement
The windows are replaced in the same manner as the
windshield. When replacing the rear window ina Saab
96, first remove the shelf over the luggage compartment
Opening side windows
Opening side windows are fitted on some models. The
only spare part available is the window glass complete
with frame.
OPENING SIDE WINDOW, SAAB 95
DOOR WINDOW
The bottom of the door window glass is pressed into a
retainer channel with a slot for the window regulator
winder arm. A hinge is fitted to the front end of the
retainer channel and secured to the door frame by means
of two screws. A run channel guides the rear edge of
the window glass.
Removal
1. Wind down the window until its rear edge is just be-
low the weather seal.
2, Remove the door trim.
3. Remove the protective paper that covers the triangu-
lar hole in the front part of the door and undo the
inner door handle remote control retainer. Note the
return spring in cars as from model 1969.
4, Back off the two retaining screws at the hinge.
843—2
REMOVING THE HINGE RETAINING SCREWS
5, Pull off the glass from the window regulator pin, twist
the glass to bring its rear end upwards and take it out
through the hole in the door.
REMOVAL OF DOOR WINDOW
6. Release the glass from the retainer channel, if neces-
sary.
Febr 1977
Page 568
Installation
1, Fit the rubber inserts in the glass retainer channel and
the glass firmly into the channel. Make sure that
4 the retainer holds the glass firmly.
er the glass at an angle from inside the door and
th the hinge at the bottom. At the same time, guide
vindow regulator pin into the slot.
twist the glass to bring the hinge up into posi-
moving the glass rearwards at the same time so
enters the run channel,
the two hinge screws and wind up the window.
djust the window at the hinge so that it fits snugly
run channel without smooth operation being
sded. Having done this, tighten the two hinge
finally.
iner door handle remote control retainer,
Page 569
UPHOLSTERY AND INTERIOR
FITMENT
pooR AND SIDE TRIMS
The door trims and side trims are attached to the doors
and body, as applicable, by means of spring clips. The
door trim can be removed, when the inner door handle,
window regulator crank and upholstery have been re-
moved. Pry off the spring clips by means of a screw driv-
er or similar, making sure that the porous wallboard do
not get teared.
DOOR PILLAR TRIM
The door pillars in the Saab 96 are fitted with trim. The
trim is fastened with tape carrying adhesive on both sides.
INSTALLATION OF DOOR PILLAR TRIM
COWL PLATE TRIM
The cardboard cowl plate trim is secured to the dash
Penel with sheet metal screws and spring clips. Insula-
tion against sound and heat is afforded by a thick quilt
Of glass fiber between the dash panel and the trim.
Febr 1977
SAAB
HEADLINING, SAAB 95
HEADLINING, SAAB 95
1. Headlining
2. Retainer
3. Wire spiral with hooks
Removal and installation
To install, first attach the headlining to the three hooks
in the upper part of the windshield frame. Then stretch
the lining rearwards while putting on the bows. Using
tool 82 90 579, fit the rear edge of the headlining over
the three hooks. Finally, stretch the longitudinal wire
spirals. These are divided in the middle and fitted with
hooks. Using two double folded steel wires, get hold of
INSTALLATION OF HEADLINING, SAAB 95
these hooks and hook them into one another. Disassemble
in the reverse order.
As from model! 1971 there is a crash pad in the form of a
plastic strip fitted on the inner edge around the roof,
850—1
Page 570
HEADLINING, SAAB 96
The headlining is stretched on piano wire bows. and re-
tained in the following way. The cloth is wrapped round
the upper edges of the frames for the windshield-, side-
and rear window strips, using tape with adhesive on both
sides when fastening.
Fitting and removal
First fit tape carrying adhesive on both sides, round the
upper edges of all the window frames and to the upper
edge of the door frames. Hang the headlining on to the
bows.
FITTING DOUBLE ADHESIVE TAPE
1. Middie mark in the roof
2. Middie mark in the headlining
Start with the rear bow, and hang this on to the rear door
pillar, with the free ends of the bow pointing forward.
Then proceed forward, hanging the other bows on in the
same way and making sure that the first bow comes as
near as possible to the windshield frame.
Fit the headlining to the windshield frame, starting at
the centre mark and proceeding towards the side. Stretch
the headlining a little. The outer edge of the headlining
shall end approx. at the score in the windshield pillar
trim. Pull the headlining backwards in the following way.
With one hand grip the last bow and pull backwards, and
at the same time, with the other hand, stretch bow by
bow backwards. Make sure that the headlining stretches
evenly. This is done by comparing the distance between
the seam at the rear border of the headlining and the
welding seam between roof and side sheet. If necessary,
the headlining can be stretched with the last bow.
850—2
IMPORTANT
Do not stretch from the headlining’s border.
Fit the headlining to the rear windshield frame, starting
at the seam on the side, thereby placing the seam upon
the welding seam between roof and side sheet. Then
fasten the headlining on towards the middle, and check
at the centre mark that the headlining is correctly posi-
tioned. Go into the car, and check that the headlining is
centred on each bow, before you raise same.
Raise all the bows, and insert the dome lamp cables
through the hole in the headlining.
LOCATION OF SIDE SEAM OVER THE WELDING SEAM BE-
TWEEN ROOF AND SIDE VALANCE
Fit the headlining to the side, starting at the last bow.
Place the seam for the last bow in the side window
frame's rear corner, and fit as far as the door pillar.
Make sure that the recess for the door pillar be correctlv
positioned. Proceed fitting the headlining as far as to the
windshield pillar. Make sure that there are no wrinkles at
the windshield pillar.
Febr 1977