Reverse Gear

1mTo dismantle
1. Fit the reverse gear in sleeve 87 90 487.





2. Carefully tap the reverse gear out of its support using a drift.
IMPORTANT: Ensure that the washer is not pressed off the shaft.





3. Lift off the bearing support, bearing washer, reverse gear pinion, synchromesh sleeve, balk ring, wire ring, reverse gear wheel and needle bearing from the reverse gear.
4. 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 and calculate an average of the readings. If the dimension is less than 0.5 mm the synchromesh must be replaced.

To assemble
Oil all parts with Saab synthetic manual gearbox oil before assembling).
1. Place the reverse shaft in a 17 mm sleeve so that the lower support washer does not become detached from the shaft.





2. Fit the needle bearing and reverse gear wheel to the shaft.
3. Fit the balk ring. Check that the wire ring is fitted to the balk ring.
4. Fit the synchromesh sleeve.





5. Fit the reverse pinion with integrated synchromesh hub.

IMPORTANT: The synchromesh hub's 3 recesses should fit over the 3 lugs on the balk ring.





6. Fit the bearing washer. Check that the washer's tag is between the lugs on the reverse shaft support.

7. NOTE:
Always use a new reverse shaft support to ensure a press fit.
Apply Loctite 648 sparingly to the shaft hole on the reverse shaft support.

8. Press on the reverse shaft support as illustrated (the holes should be aligned). Use a 17 mm sleeve and press on fully.

IMPORTANT: The reverse shaft support's screw hole must be on the opposite side from the shaft's lube hole.





9. Screw the reverse shaft into the clutch housing as this will ensure the correct position for measuring play.
Tightening torque: 24 Nm (18 ft. lbs.)
10. Check that the reverse gear is correctly assembled by measuring using a feeler gauge. Measure between the upper pinion and the thrust washer at the reverse shaft support. Play should be 0.10 - 0.20 mm.
11. Try shifting the reverse gear by pushing the synchromesh sleeve up and down.