Part 2 of 2

Install the low & reverse brake leaf spring.





(A) Leaf spring
Install the 2-4 brake piston and 2-4 brake retainer by aligning hole of 2-4 brake retainer and hole of transmission case.





(A) 2-4 brake piston
(B) 2-4 brake piston retainer
Install 2-4 brake piston return spring to transmission case.





Position snap ring in transmission. Using ST, press the snap ring into place.
ST 32005113 COMPRESSOR





Install planetary gear and low clutch assembly to transmission case.
Install carefully while rotating the low clutch and planetary gear assembly slowly paying special attention not to damage the seal ring.





Selection of 2-4 brake retaining plate (Saab 9-2X 2.0T Aero)
Install pressure plate, drive plate, driven plate, retaining plate and snap ring.





Install a new 2-4 brake oil seal to transmission case.





After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of the brake.





Check the clearance between the retaining plate and the snap ring.

Note: Select a retaining plate with a suitable value from the following table, so that the clearance becomes the standard value.

If it exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.
Initial standard: 0.8 - 1.2 mm (0.031 - 0.047 inch)
Limit thickness: 1.5 mm (0.059 inch)

Retaining plate:

Selection of 2-4 brake retaining plate (Saab 9-2X 2.5i Linear)
Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
Set the micro gauge to clutch, and read its scale.

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 100 N (10.2 kgf, 22.5 lbs.).

Put the flat board on retaining plate.





Using the following formula, calculate N indicated on the push/pull gauge.
N = 100 N (10.2 kgf, 22.5 lbs.) - Z
N: Value indicated on push/pull gauge
100 N (10.2 kgf, 22.5 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) Driven plate
(B) Drive plate
(C) Retaining plate
Install the pressure plate, drive plate, driven plate, retaining plate and snap ring.





Install a new 2-4 brake oil seal to transmission case.





After all 2-4 brake component parts have been installed, blow air intermittently and confirm the operation of brake.





Measure and record the clearance B between the retaining plate and snap ring.





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 usage 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
Initial standard: 1.7 - 2.1 mm (0.067 - 0.083 inch)
Limit thickness: 2.3 mm (0.091 inch)

Retaining plate:

Be careful not to mistake the location of the leaf spring to be inserted.





(A) Leaf spring
(B) Retaining plate
Install thrust needle bearing in the correct direction.





(A) Snap ring
(B) Thrust needle bearing
(C) Upside
(D) Downside
(E) Outside
Install front sun gear and thrust needle bearing.





(A) Front sun gear
(B) Thrust needle bearing
(C) Clutch hub side
(D) Front sun gear side
(E) Outside

Install the high clutch hub.
Attach the thrust needle bearing to the hub with Vaseline and install the hub by correctly engaging the splines of the front planetary carrier.
Install the thrust needle bearing in proper direction.





(A) High clutch hub
(B) Thrust needle bearing
(C) Upside
(D) Downside
(E) Outside
Install the high clutch assembly.





(A) High clutch and reverse clutch assembly
Adjust total end play.
Install the thrust needle bearing in proper direction.





(A) High clutch and reverse clutch ASSY
(B) Thrust needle bearing
(C) Upside
(D) Downside
(E) Outside
Install the oil pump housing assembly.
Install the converter case assembly to the transmission case assembly.
Insert inhibitor switch and transmission connector into stay.
Install air breather hose.





(A) Transmission harness
(B) Inhibitor switch harness
Install oil cooler pipes.
Install the oil charge pipe with O-ring.
Insert the input shaft while turning lightly by hand. At this time, not to damage the bushing.
Normal protrusion A: 50 - 55 mm (1.97 - 2.17 inch)





Install the torque converter clutch assembly.
Install the transmission assembly to the vehicle.

DISASSEMBLY
HIGH CLUTCH, REVERSE CLUTCH
Remove the snap ring, and take out the retaining plate, drive plates, driven plates.





(A) Snap ring
Remove snap ring, and take out the retaining plate, drive plates and driven plates.





(A) Snap ring
Using ST1 and ST2, remove snap ring.
ST1 32005075 COMPRESSOR
ST2 32005112 SEAT





(A) Snap ring
Take out clutch cover, spring retainer, high clutch piston and reverse clutch piston.





(A) Reverse clutch piston
(B) Cover
(C) Return spring
Remove seal rings and lip seal from high clutch piston and reverse clutch piston.





(A) High clutch piston
(B) Reverse clutch piston

PLANETARY GEAR, LOW CLUTCH
Remove snap ring from the low clutch drum.





(A) Snap ring
(B) Low clutch drum
Take out front planetary carrier.





(A) Front planetary carrier
(B) Low clutch drum
Take out rear sun gear.





(A) Rear sun gear
(B) Rear planetary carrier
Take out rear planetary carrier, washer and thrust needle bearing.





(A) Rear planetary carrier
(B) Low clutch drum
Take out rear internal gear.





(A) Rear internal gear
(B) Low clutch drum
Remove the snap ring from the low clutch drum.





(A) Snap ring
(B) Low clutch drum
Compress the spring retainer, and remove the snap ring from the low clutch drum, by using ST1 and ST2.





ST1 32005112 SEAT
ST2 32005075 COMPRESSOR
(A) Snap ring
(B) Low clutch drum

Remove one-way clutch.
Install the one-way clutch inner race to the low clutch drum, and apply compressed air to remove the low clutch piston.





(A) Apply compressed air
(B) One-way clutch inner race
Remove the one-way clutch inner race.
Remove the one-way clutch after taking out the snap ring.





(A) Snap ring
(B) Plate
(C) One-way clutch
Remove the needle bearing after taking out the snap ring.





(A) Needle bearing
(B) Snap ring

2-4 BRAKE
Separate 2-4 brake piston and piston retainer.





(A) 2-4 brake piston
(B) 2-4 brake piston retainer
Remove the D-ring from 2-4 brake piston.

ONE-WAY CLUTCH INNER RACE
Remove seal rings.





(A) One way clutch inner race
(B) Seal rings
Using ST, remove needle bearing.
ST 32005071 PULLER ASSY

ONE-WAY CLUTCH OUTER RACE
Remove the one-way clutch after taking out the snap ring.





(A) Snap ring
(B) Plate
(C) One-way clutch
Remove the needle bearing after taking out the snap ring.





(A) Needle bearing
(B) Snap ring