To Assemble

General measures before assembly
Parts and housing should be thoroughly washed before assembly.
^ Check the parts for wear. Change damaged or defective parts.
^ If there was a lot of swarf in the gearbox, all bearings should be replaced. Always change both bearings on one shaft, even if only one is damaged.
^ Change seals at the drive shafts.
^ All bearings and friction areas should be oiled before fitting with same type of oil as used in the gearbox (Saab synthetic manual gearbox oil).





1. Secure the clutch housing in a work fixture with transmission holder 87 92 228.
2. Carefully scrape off remains of sealant from the mating face without damaging the surface. Make sure the gearbox is clean of sealant remains.
3. Position the differential in the clutch housing and lubricate the bearing.





4. Position the output shaft in its seat, grease the bearing and position the bearing race. Position a bearing support and tap the bearing race down using sleeve 87 92 202 and sleeve bearing race 87 91 204. Apply threadlock Loctite 242 part no 74 96 268, to all bolts and fit them. Tighten the 3 centre bolts alternately.
Tightening torque 45 Nm (33 ft. lbs.).
The outer bolts should only be tightened to:
Tightening torque 24 Nm (18 ft. lbs.)





5. Fit gear wheels for the 1st and 2nd gears with synchromesh assembly on the output shaft with assembly fixture 87 92 103. Then fit the assembled parts on the output shaft. Fit 3rd gear and spacer sleeve on the output shaft. Note that a used gear must face the same way as before. Do not let the mounted wheels go too far down on the shaft, save 15 mm. Otherwise the input shaft cannot be fitted.
6. Place the input shaft in the housing and lubricate the bearing. Fit a cable tie to keep the gears on the input and output shafts meshed.





7. Carefully press down the wheels on the output shaft against the plane on the clutch housing. Tap carefully with a hammer and sleeve 87 91 204 and assembly ring 87 90 867 until a new retaining sleeve and the 4th gear wheel can be fitted. Turn the 4th gear wheel so that the machined groove faces down.





8. Fit puller 87 91 251 and pull down until 4th gear's pinion and gear wheel on the input and output shafts are level with each other. Cut the cable ties and remove the assembly tool 87 92 103. Check that 1st and 2nd gears' pinions run easily on the output shaft.





9. Lift the input shaft a little and fit the reverse gear wheel with pinion and synchromesh. The hole in the reverse shaft should be facing the channel in the clutch housing.

IMPORTANT: If the lube hole is facing the other way, the reverse gear is incorrectly assembled. If this is the case, correct the fault.





10. Fit the selector mechanism to the clutch housing. The forks should be in the neutral position. Push up the synchromesh sleeve to the 2nd synchromesh position on the output shaft. Push up the synchromesh sleeve to the 4th synchromesh position on the input shaft.
11. Place the 1st-2nd and 3rd-4th forks in the synchromesh sleeves and turn and push the mechanism into position. The synchromesh sleeves should be in the neutral position. Insert the locating sleeves and align the screws.





12. Fit the reverse gear selector fork with the two remaining bolts. Use Loctite 577 threadlock, part no (16) 74 96 284 on the short bolt (the screw hole leads to the clutch housing; the threadlock prevents oil leaks). Tighten the 3 bolts.
Tightening torque 24 Nm (18 ft. lbs.)

IMPORTANT: The oil plate for the reverse gear selector fork should be fitted under the edge of the selector mechanism.





13. Fit the fork to the reverse synchromesh sleeve. Check that the reverse gear selector fork enters the groove on the reverse fork. Then push in the shaft. Engage reverse gear using the selector mechanism and check that it Is fully engaged.





14. Fit a new seal. Fit the selector rod in position, lubricate the seal.
15. Insert and fit the driver. Push in the selector rod and fit the screw.
Tightening torque 24 Nm (18 ft. lbs.)





16. Check that all gears can be engaged. Also check the dual interlock feature by engaging 1st and then attempting to engage reverse by pushing in the reverse gear fork using a screwdriver. If reverse can be engaged, the locking pin in the selector mechanism must be checked.





17. Clean the contact surfaces thoroughly with Loctite Superclean 7063, part no. 30 02 599. Sparingly apply Loctite 518, part no. 93 21 795, to the contact surfaces of both the gearcase and the clutch housing. Spread the Loctite and let it dry for a couple of minutes.

IMPORTANT: When assembling the gearbox and applying Loctite, greatest care must be taken. If the sintered plug (at arrow) in the gearbox vent is blocked, oil from the gearbox can be forced out past the shaft seals.





18. Check that the reverse shaft support is correctly positioned so that the screw can be fitted after the gearcase has been fitted. Place the gearcase on the clutch housing.

IMPORTANT: Cover the holes in the gearcase so that nothing can accidentally get into the gearbox.





19. First fixate the clutch housing and gearcase slightly with two screws. Then tap up the locating sleeves. Fit the screw for the reverse shaft loosely.
If necessary, use a narrow screwdriver to line up the screw hole with the hole in the gearcase. Fit the rest of the bolts.
Tightening torque 24 Nm (18 ft. lbs.)





20. Tighten the screw for the reverse shaft. Note the O-ring!
Tightening torque 24 Nm (18 ft. lbs.)
21. Tighten the screw for the reverse shaft support.
Tightening torque 28 Nm (21 ft. lbs.)





22. Fit the bearing on the output shaft, lubricate the bearing and pull it using puller 87 91 261. Pull only until it touches the retaining sleeve.
23. Fit the 5th gear wheel on the output shaft. Tap down the 5th gear wheel slightly with a hammer and sleeve 78 41 067. Fit puller 87 91 261. Then pull the gear wheel against the bearing with the tool and fit a new nut.

IMPORTANT: Lubricate the threads and faces of the nut with gearbox oil.





24. Fit driver 87 91 428 on the input shaft. Position the dial gauge measuring point on the input shaft bearing. Fit a drill on the tool and "run" the gearbox so that the bearings settle into position. First press and run 20 revolutions and then zero the gauge. Lift and run another 20 revolutions and read off (or until the value has stabilized). Measure the end float, it should be 0.09 - 0.15 mm. (Float will decrease to 0.04 - 0.11 mm when the output shaft bearing is adjusted to the correct preload.) Adjust with shims under the bearing support if needed. Shims are available in dimensions 0.10, 0.15 and 0.30 mm.
^ Thicker shims = increase play
^ Thinner shims = reduce play
Shims are available in dimensions 0.10; 0.15; 0.30 mm

IMPORTANT: Carefully tap the primary shaft using a plastic hammer so that the bearing race at the 5th pinion is against the bearing support.

25. When adjusting axial play on input shaft:
Undo and remove the 4 screws from the bearing support. Refit the bearing support together with the correct package of shims and tighten alternately.
Tightening torque 38 Nm (28 ft. lbs.)
Check play again. Remove the three tools.





26. Fit support 87 92 517 as support for the input shaft when the 5th gear synchromesh hub is tapped down.
27. Fit the 5th pinion with needle bearing. Lubricate the bearing.





28. Fit the wire ring, the 3 leaf springs, balk ring and hub with assembly fixture 87 92 582. The hub is tapped down with sleeve 78 41 067 onto the splines of the input shaft.
29. Remove assembly fixture 87 92 582.
30. Fit the 5th synchromesh sleeve with the tip angles down.
31. Remove supported 87 92 517.





32. Fit the dial gauge kit 87 92 194 against the gear wheel with stand 87 90 727. Engage 1st gear and press down the 5th gear synchromesh sleeve so that the gearbox "locks". Tighten the nut and measure in turns with the dial indicator until the end play of the output shaft is 0.06 ± 0.05 mm. Use a short M 8 bolt on the sealing surface as a lever. Disengage 1st and 5th gears.

IMPORTANT: Do not lever directly under the gear teeth. Insert the screwdriver well under.





33. Check and adjust the preload of the differential as follows:
Fit around bearing race 87 92 137 instead of the earlier removed bearing race. Remove the bearing support O-ring. Fit a shims package of approx. 2 mm together with the bearing support.





34. Position weight 87 92 095 on the bearing support. Fit driver 87 92 053 on the output shaft. Use a drill to run in the differential at least 20 revolutions. Check the float with a feeler gauge in at least three places between the bearing support and the gearbox casing. Use the average value of the measured values and adjust the shims package so that the average value is according to the following table:





Nominal Value For Differential Preload

^ Thicker shims = increase preload
^ Thinner shims = reduce preload
^ Shims for the differential are available in sizes 0.10, 0.15, 0.30, 0.50 mm

WARNING: Watch your fingers when the pinions are moving.

35. Lift off weight 87 92 095, differential bearing support and the around bearing race 87 92 137.

IMPORTANT: Do not forget to replace tool 87 92 137 with the bearing race. Risk of damaging the gearbox.

36. Tap down the bearing race slightly using sleeve 83 90 114. Fit and lubricate the O-ring on the bearing race. Fit the bearing support with a shim package of the calculated dimension. Loosely tighten the bolts and then tighten the bearing support until a nominal value of plus 0.15 mm remains.

IMPORTANT: The bearing support is torque tightened after checking the preload of the output shaft. There must be a certain amount of axial play so as not to interfere with the measurement of bearing preload on the output shaft.

37. Turn the gearbox so that it is in the same position as it would be in the car, i.e. horizontal.





38. Fit the M8 fuel hose (approx. 100 mm long) between driver 87 91 428 and Allen socket (M8 with 1/2" drive). Check that no gear is engaged.

IMPORTANT: The torque wrench is sensitive to blows, overloading and rough handling.

39. Connect the torque wrench (graduated in Nm) and rotate the wrench clockwise several revolutions at even speed. Read off the average value while rotating, normally 0.10 - 0.30 Nm. (Applies to new bearings)
Note the value (applies to new bearings) in the table at step 49 under "Read value, input shaft". The value will be used for calculating the correct torque for the output shaft.
If the value is greater than 0.30 Nm or if it varies greatly while rotating, either the balk rings or dirt and cuttings in the bearing are slowing it down. Dismantle the gearbox and investigate the cause. Rotating the shaft backwards and forwards under axial load may help. The bearings must be oiled in later, however.
40. Turn the gearbox back around.





41. Place the tip of the dial indicator on the shaft as shown in the illustration Fit the driver 87 92 053 on the output shaft and "run" the gearbox with a drill so that the bearings settle. Press and first run 20 revolutions and then zero the gauge. Lift and run a further 20 revolutions and note the gauge reading (or until the reading has stabilized). Remove the tool. Note the measured value for end float and then add the nominal value. Remove the dial indicator.

WARNING: Watch your fingers when the pinions are moving.

42. Engage 5th gear by pushing down the synchromesh sleeve. Engage 1st gear.





43. Remove driver 87 92 053 from the output shaft.





44. Fit millimeter disc 87 92 061 to the output shaft nut. Set the tool's (mm disc) scale to the calculated value (measured + nominal, see example). Mark a tooth on the gear wheel with a felt pen or the like. Each graduation corresponds to 0.01 mm.





Example: Measured value 0.43 + 0.03 (nominal value, above 5 000 km) = 0.46 mm.
Only check the rolling torque for new bearings.





45. Tighten in 2-3 stages until zero (O) mark on the tool (mm disc) is aligned with the marked tooth. Measure the end float as described in steps 41-45. Remove the tool and the sleeve.
If old bearings are fitted to the output shaft, lock the nut and continue with step 52.
If new bearings are fitted, do not lock the nut and continue with the next step.





46. Before taking a more precise measurement of the output shaft bearing preload, the following must be complied with:
Input shaft bearing (axial play 0.09 - 0.15 mm)
The differential and bearing support fitted but not tightened. Clearance between gearcase and bearing support should be nominal value plus 0.15 mm.
All bearings oiled
47. Turn the gearbox so that it is in the same position as it would be in the car, i.e. horizontal. Disengage 1st gear and lift off the 5th synchromesh sleeve.
48. Place the torque wrench at the 5th gear nut output shaft. No gear must be engaged. Rotate the torque wrench several turns clockwise at an even speed. Read the average value from the display during rotation.
The read value is the total rolling torque for the input and output shafts.
To be able to set the correct rolling torque value, it must first be calculated.





Calculate the total torque as in the following example.
Tighten the nut for the output shaft two markings at a time on the millimeter disc 87 92 061, until the calculated total rolling torque is achieved.
Average torque varies greatly:
Cause:
Retarding balk rings, swarf or dirt in the bearings.
Action:
Dismantle the gearbox and rectify the fault.
Average torque higher than 1.3 Nm:
Cause:
Same as above or bearings too tight
Action:
Dismantle the gearbox and change clamping sleeve. The bearings should then be preloaded and checked.

50. Lock the nut
51. Turn the gearbox back around.





52. Lift off the 5th synchromesh sleeve and fit the 5th fork to the 5th synchromesh sleeve. Fit the fork and sleeve to the shaft.

NOTE: Note that the synchromesh sleeve may only be placed on the synchromesh hub when the high lugs on the sleeve are opposite the tooth gaps on the synchromesh hub that are opposite the deep tooth gaps as illustrated.

53. Tap the retention pin into the selector shaft.
54. Fit a new locking ring.
55. Tighten the screws for the differential bearing support.
Tightening torque 24 Nm (18 ft. lbs.)





56. Remove the cover from the hole in the gearcase and fit a new gasket and the end cover.
Tightening torque 24 Nm (18 ft. lbs.)
57. Refit the reversing-light switch with a new gasket.
Tightening torque 24 Nm (18 ft. lbs.)





58. Check that the magnet is in position in the oil drain plug. Fit the plug.
Tightening torque 50 Nm (37 ft. lbs.)
59. Lubricate the seal rings for input shaft and drive shafts.
60. Fill with oil only after fitting the drive shafts to the gearbox and fitting the gearbox in the car. Oil volume: 1.9 Liters.
61. Fit the slave cylinder applying threadlock Loctite 577 to the bolts.
Tightening torque 10 Nm (7 ft. lbs.)
62. Fit delivery pipe in place and fit the bush.





63. Lower the gearcase and remove the holder.
64. Bleed the slave cylinder before the gearbox is mounted.