Part 1 of 2
AT Main CaseREMOVAL
Remove the transmission assembly from the vehicle.
Extract the torque converter clutch assembly.
Remove the input shaft.
Lift-up lever behind the transmission harness connector and disconnect it from stay.
Disconnect inhibitor switch connector from stay.
Disconnect the air breather hose.
Remove the oil charge pipe.
Remove the oil cooler inlet and outlet pipes.
Separation of converter case and transmission case.
Remove the oil pump housing.
Take out the high clutch, thrust needle bearing and reverse clutch assembly.
(A) High clutch and reverse clutch assembly
(B) Thrust needle bearing
Take out the high clutch hub and the thrust bearing.
(A) High clutch hub
(B) Thrust needle bearing
Take out the front sun gear and the thrust bearing.
(A) Front sun gear
(B) Thrust needle bearing
Pull out leaf spring without folding.
Note: Remove it while pressing down on lower leaf spring.
(A) Leaf spring
(B) Retaining plate
Remove snap ring and thrust needle bearing.
(A) Snap ring
(B) Thrust needle bearing
Take out retaining plate, drive plate and driven plate of 2-4 brake.
Take out the thrust needle bearing, planetary gear assembly and the low clutch assembly.
Remove 2-4 brake seal.
Remove snap ring.
(A) Snap ring
(B) 2-4 brake piston
Take out 2-4 brake return spring.
Remove the 2-4 brake piston and piston retainer without damaging.
(A) 2-4 brake piston
(B) 2-4 brake piston retainer
Pull out the leaf spring without folding.
(A) Leaf spring
Remove snap ring.
(A) Snap ring
Take out retaining plate, drive plate, driven plate and dish plate.
Turn the transmission case upside down, and then take out the socket bolts while holding the one way clutch inner race with hand.
Take out the spring retainer.
Take out the return spring.
Apply compressed air.
Take out the low & reverse piston.
INSTALLATION
Install the low & reverse piston without tilting.
Note: Be careful not to damage the lip seal.
Install return spring.
Install spring retainer.
Install the one-way clutch inner race, spring retainer and return spring.
Tighten socket head bolts evenly from the rear side of the transmission case.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
Place the front side of transmission body up.
Install thrust needle bearing.
Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
Set the micro gauge to retaining plate, and read its scale. Make more than three measurements at even distance and take the average value.
Note: The value, which is read in the gauge at this time, is zero point.
Scale and record the weight Z of a flat board which will be put on plates.
Note:
^ Use a stiff flat board which does not bend against load.
^ Use a flat board of its weight less than 83 N (8.5 kgf, 18.7 lbs.).
Put the flat board on retaining plate.
Using the following formula, calculate N indicated on the push/pull gauge.
N = 83 N (8.5 kgf, 18.7 lbs.) - Z
N: Value indicated on push/pull gauge
83 N (8.5 kgf, 18.7 lbs.): Load applied to clutch plate
Z: Flat board weight
Press the center of retaining plate applying force of N with push/pull gauge, and then measure and record the height A. Make more than three measurements at even distance and take the average value.
Note: If three points, measure the height every 120°. If four points, measure the height every 90°.
(A) Dish plate
(B) Driven plate
(C) Drive plate
(D) Retaining plate
Installation of the low & reverse brake:
Install the dish plate, driven plate and retaining plate, and then secure them with snap ring.
Note: Pay attention to the orientation of dish plate.
(A) Snap ring
Apply compressed air intermittently to check for operation.
Place the same thickness of shim on both sides to prevent the plate from tilting, and then measure and record the clearance B.
Note: Do not press the shim downward with excessive force, or else the waveform of drive plates will be broken down.
Piston stroke calculation
Select the retaining plate within the specification by calculating with A and B dimensions which have been recorded before. If the calculated value exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.
T = A + B
T: Piston stroke
A: Collapse amount of drive plate
B: Clearance between retaining plate and snap ring
Saab 9-2X 2.5i Linear
Initial standard: 2.15 - 2.65 mm (0.073 - 0.093 inch)
Limit thickness: 2.95 mm (0.104 inch)
Saab 9-2X 2.0T Aero
Initial standard: 2.70 - 3.20 mm (0.106 - 0.126 inch)
Limit thickness: 3.90 mm (0.154 inch)
Retaining plate (Part 1):
Retaining plate (Part 2):
