To Assemble

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 surfaces must be oiled in before mounting using the same type of oil as found in the gearbox (Saab synthetic manual gearbox oil). See List of lubricants and sealants.





1. Place the clutch housing in a work stand with 87 92 228 Holder, transmission.
2. Carefully scrape away old sealant residue from the mating surface without damaging the surfaces. Be sure to clean sealant residue from the gearcase.
3. Position the differential in the clutch housing and lubricate the bearing.





4. Set the output shaft in its seat, lubricate the bearing and align the bearing race. Add a bearing support and tap down. Use 87 92 202 Sleeve and 87 91 204 Sleeve, bearing race. Use locking compound Loctite 242 part no. (16) 74 96 268 on all screws and mount them.
Tighten the 3 screws in the centre 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 the gear wheels for 1st and 2nd gear with the synchromesh assembly on the output shaft with 87 92 103 Assembly fixture I. 1st and 2nd gear hubs. Then fit the assembled parts on the output shaft. Fit the gear wheel for 3rd gear and spacer sleeve on the output shaft. Note that a used pinion must be turned 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. Press down the wheel on the output shaft against the plane of the clutch housing. Carefully tap with a hammer and 87 91 204 Sleeve bearing race and 87 90 86Z Assembly ring bearing input shaft until a new clamping sleeve can be added to 4th gear's wheel. Turn 4th gear's wheel so that the grooves are down.





8. Fit 87 91 261 Puller pinion and pull down until 4th gear's pinion and wheel on the input and output shafts lie even with each other. Cut off the cable tie and remove 87 92 103 Assembly fixtures 1st and 2nd gear hubs. Check that 1st and 2nd gears' pinions move 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 screws. Use thread sealant Loctite 577 part no. (16)74 96 284 (See List of lubricants and sealants) for the short screw (The screw hole ends in the clutch housing. Thread sealant prevents oil leakage). Tighten the three screws.
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 sealing surfaces thoroughly with Loctite super clean 7063 part no. 30 02 599. Apply Loctite 518, part no. 93 21 795 sparingly (See List of lubricants and sealants ) on the contact surfaces of both the gearcase and the clutch housing. Apply the Loctite and allow to dry for a few 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. Place the bearing on the output shaft, lubricate the bearing and pull it with 87 91 261 puller pinion. Pull only until the clamping sleeve catches.
23. Place 5th gear's wheel on the output shaft. Tap down 5th gear's wheel slightly with a hammer and 78 41 062 Sleeve bearing inner driver. Fit 87 91 261 Puller pinion. Then pull the wheel toward the bearing with the tool and fit a new nut.

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





24. Fit 87 91 428 Driver on the input shaft. Position the dial indicator probe tip on the input shaft bearing. Fit a drill on the tool and "run" the gearbox so that the bearings "settle in". First run 20 revolutions and reset the dial indicator. Lift and run another 20 revolutions and read off the value (or until the value has stabilized). Check the axial play. The axial play should be 0.09 - 0.15 mm. (The play will decrease to 0.04 - 0.11 mm when the output shaft bearings are adjusted to the correct pretension.) Adjust with shims under the bearing support if needed. Shims are available in dimensions 0.10; 0.15; 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 shim combination and tighten alternately.
Tightening torque 38 Nm (28 ft. lbs.)
Check play again. Remove the three tools.





26. Fit 87 92 517 Support, input shaft as a 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. Assemble the wire ring, the 3 leaf springs, the baulk ring and the hub with87 92 582 Fixture, 5th gear synchromesh hub. Tap down the hub with 78 41 067 Sleeve, bearings inner driver on the input shaft splines.
29. Remove 87 92 582 Fixture 5th.gear synchromesh hub.
30. Fit the 5th synchromesh sleeve with the tip angles down.
31. Remove 87 92 517 Support, input shaft.





32. Fit 87 92 194, Kit dial indicator against the gear wheel with stand 87 90 727. Engage 1st gear and press down 5th gear's synchromesh sleeve so that the gearbox "locks". Tighten the nut and measure periodically with the dial indicator until the output shaft has axial play of 0.06 +0.05 mm. Use a short M8 screw in the seal plane as breakpoints. Disengage 1st and 5th gear.

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 87 92 137 Ground bearing race instead of the previously removed bearing race. Remove the bearing support O-ring. Fit a shim combination, approximately 2 mm, together with the bearing support.





34. Place 87 92 095 Weight, differential beacon the bearing support. Fit 87 92 053 Driver on the output shaft. Use a drill to run the differential at least 20 revolutions. Use a feeler gauge to measure clearance in three places between the bearing support and the gearcase. Take the average of the three readings and adjust the shim combination so the average is that indicated in the table:





^ 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. Remove 87 92 095 Weight differential bearing, differential bearing support and 87 92 137 Ground bearing race.

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





36. Use 83 90 114 Sleeve, 4th gear pinion to tap down the bearing race a bit. Fit and lubricate the O-ring on the bearing support. Fit the bearing support with measured shim combination. Loosen the bolts and then tighten the bearing support until there is a nominal value plus 0.15 mm.

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 (approximately 100 mm long) between 87 91428 Driver 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)
If the value is greater than 0.30 Nm or if it varies greatly while rotating, either the baulk 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. Position the dial indicator probe tip on the shaft as indicated. Fit 87 92 053 Driver on the output shaft and "run" the gearbox with a drill until the bearings "settle in". First run 20 revolutions and then reset the dial indicator. Lift and run another 20 revolutions and read off the value (or until the value has stabilized). Remove the tool. Note the reading for axial play 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 87 92 053 Driver from the output shaft.





44. Fit 87 92 061 Metric..disc. 27 mm on the output shaft nut. Set the tool's (metric disc's) scale marking to the calculated value (measure + nominal. See example). Mark a cog on the gear wheel with a felt-tip pen or the like. Each line equals 0.01 mm.





Example: Measured value 0.43 + 0.03 (nominal value, over 5000 km) = 0.46 mm.

Check the roll torque only for new bearings.





45. Pull in 2-3 stages until the tool's (metric disc's) zero (0) mark is at the marked cog. Measure axial play again following 41-45 to ensure that the correct prestress has been obtained. Remove the tool and sleeve.
If an old bearing is fitted on the output shaft, lock the nut and continue with p 52.
If a new bearing is fitted, do not lock the nut and continue with the next point.
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)
Differential, bearing support fitted but not tightened (axial play 0.10 - 0.20).
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.
49. The reading should be 0.5 - 1.0 Nm.
Tighten the nut on the output shaft (5th and 1st gears engaged) two lines of the millimeter markings at a time on 87 92 061 Metric disc, 27 mm until the correct roll torque is obtained (0.5 - 1.0 Nm).
Average torque varies greatly:
Cause:
Retarding baulk rings, swarf or dirt in the bearings.
Action:
Dismantle the gearbox and rectify the fault.
Average torque higher than 1.0 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. If the reversing light switch has been removed, fit it 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. Oil is not filled until the drive shafts are fitted on the gearbox and the gearbox is mounted in the car. Oil volume: 1.9 liters. See Gearbox.
61. Fit the slave cylinder and use thread seal Loctite 577 on the screws. See List of lubricants and sealants.
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.