Input Shaft

To dismantle
1. Mount the shaft in a vice with protective jaws.





2. Remove circlip.





3. Press the bearing off the shaft. Use puller 87 92 152.and basic tool 87 91 642.

IMPORTANT: A bearing which has been removed must not be refitted.





4. Lift off the 4th pinion, synchromesh and needle bearing. Keep the leaf springs in a safe place.





5. Slightly lift the synchromesh sleeve and hold with your hand so that the spring-loaded rollers do not come out. Keep the rollers in a safe place.
6. Lift off the synchromesh sleeve.

IMPORTANT: Note the position of the sleeve. If it is to be refitted, it should be refitted facing the same way.





7. Keep springs and plungers.
8. Remove the washer and circlip which secure the synchromesh hub. Remove the hub and keep the leaf springs.





9. Lift off the 3rd synchromesh, pinion and needle bearing.
10. Check the condition of all parts as regards wear. Replace damaged or defective parts. Measure the wear on the synchromesh by fitting it in place. Measure with a feeler gauge in three places between the balk ring and the pinion. Calculate an average of the readings. New synchromesh 0.8 - 1.1 mm. Win dimension is 0.5 mm. If the dimension is less, the synchromesh is worn out and must be replaced.

To assemble
All components are to be lubricated with Saab synthetic transmission oil before fitting.
1. Mount the input shaft in a vice with protective jaws.





2. Fit the 3rd pinion with needle bearing and balk ring.





3. Fit the synchromesh hub and make sure the recess for the circlip washer is face up. Make sure the hub goes down over the balk ring and insert leaf springs. If necessary, use sleeve 87 92 202 *
4. Fit the washer with a new circlip. The circlip is to be fitted with the sharp edge face up. The lock washer is fitted with the inner sharp edge fitted towards the circlip.
5. Check the axial clearance between the 2nd and 3rd gear pinions. The clearance should be between 0.05 - 0.40 mm.





6. Fit springs and plungers.





7. Fit the synchromesh sleeve.

IMPORTANT: The high lugs on the sleeve should lie in the deep tooth gaps in the hub.





8. Fit the rollers. They are fitted by pressing in the springs. A small screwdriver can be used to press in the springs.





9. Fit the 4th balk ring, leaf springs, needle bearing and pinion.





10. Make sure the bearing is turned the right way and press on a new bearing closest to the 4th gear. Use the sleeve from puller 87 91 261*. Fit a new circlip with the bevelled edge face up.

IMPORTANT: Open the circlip carefully during assembly, only enough to allow it to be fitted to the shaft. Opening the circlip too far will damage it. Carefully tap the circlip into the shaft groove using a drift.





11. Check the play between bearing and 4th pinion to ensure that the input shaft is correctly fitted. Play should be 0.05 - 0.40 mm.