Part 3
ASSEMBLYHIGH CLUTCH, REVERSE CLUTCH
Install seal rings and lip seal to high clutch piston and reverse clutch piston.
Install high clutch piston to reverse clutch piston.
(A) High clutch piston
(B) Reverse clutch piston
Install reverse clutch to high clutch drum.
Align the groove on the reverse clutch piston with the groove on the high clutch drum during installation.
(A) Reverse clutch piston
(B) High clutch drum
Install spring retainer to high clutch piston.
(A) Return spring
(B) High clutch drum
Install ST to high clutch piston.
ST 32005102 HIGH CLUTCH PISTON GUIDE
Avoid folding the high clutch piston seal, when installing the cover to high clutch piston.
Using ST1 and ST2, install snap ring.
ST1 32005075 COMPRESSOR
ST2 32005112 SEAT
ST3 32005102 HIGH CLUTCH PISTON GUIDE
Selection of high clutch retaining plate (Saab 9-2X 2.0T Aero)
Install the thickest driven plate to piston side, and then install the driven plate, drive plate, retaining plate to high clutch drum.
Install snap ring to high clutch drum.
Apply compressed air intermittently to check for operation.
Measure the clearance between the retaining plate and snap ring. (High clutch) At this time, do not press down retaining plate.
Initial standard: 0.8 - 1.1 mm (0.031 - 0.043 inch)
Limit thickness: 1.5 mm (0.059 inch)
(A) Thickness gauge
If specified tolerance limits are exceeded, select a suitable high clutch retaining plate. If it exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.
High clutch retaining plate (Part 1):
High clutch retaining plate (Part 2):
Selection of high clutch 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 250 N (25.5 kgf, 56.2 lbs.).
Put the flat board on retaining plate.
Using the following formula, calculate N indicated on the push/pull gauge.
N = 250 N (25.5 kgf, 56.2 lbs.) - Z
N: Value indicated on push/pull gauge
250 N (25.5 kgf, 56.2 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 thickest driven plate to piston side, and then install the driven plate, drive plate, retaining plate to high clutch drum.
Install the snap ring to high clutch drum.
Apply compressed air intermittently to check for operation.
Measure and record the clearance B between the retaining plate and snap ring. (High clutch)
At this time, do not press down the retaining plate.
(A) Thickness gauge
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: 2.0 - 2.3 mm (0.079 - 0.091 inch)
Limit thickness: 2.6 mm (0.102 inch)
High Clutch Retaining Plate (Part 1):
High Clutch Retaining Plate (Part 2):
Selection of reverse clutch retaining plate (Saab 9-2X 2.0T Aero)
Install driven plate, drive plate, retaining plate and snap ring.
Apply compressed air intermittently to check for operation.
Measure the clearance between the retaining plate and snap ring. (Reverse clutch) At this time, do not press down retaining plate.
Initial standard: 0.5 - 0.8 mm (0.020 - 0.031 inch)
Limit thickness: 1.2 mm (0.047 inch)
(A) Thickness gauge
If specified tolerance limits are exceeded, select a suitable high clutch retaining plate.
If it exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.
Reverse Clutch Retaining Plate:
Selection of reverse clutch 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 150 N (15.3 kgf, 33.7 lbs.).
Put the flat board on retaining plate.
Using the following formula, calculate N indicated on the push/pull gauge.
N = 150 N (15.3 kgf, 33.7 lbs.) - Z
N: Value indicated on push/pull gauge
150 N (15.3 kgf, 33.7 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) Driven plate
(B) Drive plate
(C) Retaining plate
Install the driven plate, drive plate, retaining plate and snap ring.
Apply compressed air intermittently to check for operation.
Measure and record the clearance B between the retaining plate and snap ring. (Reverse clutch)
At this time, do not press down the retaining plate.
(A) Thickness gauge
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: 1.1 - 1.4 mm (0.043 - 0.055 inch)
Limit thickness: 1.6 mm (0.063 inch)
Reverse Clutch Retaining Plate:
PLANETARY GEAR, LOW CLUTCH
Install D-ring to low clutch piston.
Fit the low clutch piston to the low clutch drum.
(A) Low clutch piston
(B) Low clutch drum
Install spring retainer to low clutch piston.
(A) Spring retainer
(B) Low clutch drum
Install ST to low clutch drum.
ST 32005103 LOW CLUTCH PISTON GUIDE
Set the cover on the piston with a press using ST1 and ST2, and attach the snap ring. At this time, be careful not to fold cover seal during installation.
ST1 32005112 SEAT
ST2 32005075 COMPRESSOR
ST3 32005103 LOW CLUTCH PISTON GUIDE
Install the dish plate, driven plates, drive plates, and retaining plate, and secure with the snap ring.
(A) Snap ring
(B) Low clutch drum
(C) Dish plate
(D) Low clutch piston side
Check the low clutch for operation.
Remove one-way clutch.
Set the one-way clutch inner race, and apply compressed air for checking.
(A) Apply compressed air
(B) Low clutch drum
Checking low clutch clearance.
Place the same thickness of shim on both sides to prevent retaining plate from tilting.
Inspect clearance between retaining plate and operation of the low clutch.
Initial standard: 0.7 - 1.1 mm (0.028 - 0.043 inch)
Limit thickness: 1.6 mm (0.063 inch)
(A) Thickness gauge
(B) Low clutch drum
If the clearance is out of the specified range, select a proper retaining plate so that the standard clearance can be obtained.
Available Retaining Plate:
If it exceeds the service limit, replace the drive plate with a new one and adjust it to the specification.
Install washer to rear internal gear.
(A) Rear internal gear
(B) Washer
Install rear internal gear.
(A) Rear internal gear
(B) Low clutch drum
Install thrust needle bearing in the correct direction.
(A) Thrust needle bearing
(B) Low clutch drum
Install the washer by aligning protrusion of washer and hole of rear planetary carrier.
(A) Washer
(B) Rear planetary carrier
Install rear planetary carrier to low clutch drum.
(A) Rear planetary carrier
(B) Low clutch drum
Install thrust needle bearing in the correct direction.
Install the rear sun gear in proper direction.
(A) Rear sun gear
(B) Rear planetary carrier
Install the thrust needle bearing in proper direction.
(A) Thrust needle bearing
(B) Front planetary carrier
(C) Rear sun gear side
(D) Front planetary carrier side
Install front planetary carrier to low clutch drum.
(A) Front planetary carrier
(B) Low clutch drum
Install snap ring to low clutch drum.
(A) Snap ring
(B) Front planetary carrier
Install the needle bearing, and secure with the snap ring.
(A) Needle bearing
(B) Snap ring
Install the one-way clutch, one-way clutch inner race and plate, and secure with the snap ring.
Set the inner race. Make sure that the clutch is locked in the clockwise direction and free in the counterclockwise direction.
(A) Locked
(B) Free
2-4 BRAKE
Apply ATF to new D-ring, and install it to 2-4 brake piston.
Install 2-4 brake piston to 2-4 brake piston retainer.
(A) 2-4 brake piston
(B) 2-4 brake piston retainer
ONE-WAY CLUTCH INNER RACE
Using a press and ST, install the needle bearing to the inner race.
ST 32005065 INSTALLER
Apply Vaseline to the groove of the inner race and to the seal ring.
Install two seal rings to one-way clutch inner race.
(A) One way clutch inner race
(B) Seal rings
ONE-WAY CLUTCH OUTER RACE
Install the needle bearing, and secure with the snap ring.
(A) Needle bearing
(B) Snap ring
Install the one-way clutch, one-way clutch inner race and plate, and secure with the snap ring.
Set the inner race. Make sure that the clutch is locked in the clockwise direction and free in the counterclockwise direction.
(A) Locked
(B) Free
INSPECTION
HIGH CLUTCH AND REVERSE CLUTCH
Inspect the following items.
^ Drive plate facing for wear and damage
^ Discoloration of driven plate (Burnt color)
^ Snap ring for wear, return spring for setting and breakage, and snap ring retainer for deformation
^ Lip seal and D-ring for damage
^ Piston and drum check ball for operation
^ Adjust total end play.
PLANETARY GEAR AND LOW CLUTCH
Inspect the following items.
^ Drive plate facing for wear and damage
^ Discoloration of driven plate (Burnt color)
^ Snap ring for wear, return spring for breakage or setting, and spring retainer for deformation
^ Lip seal and D-ring for damage
^ Piston check ball for operation
^ Measure the total end play and adjust to within specifications.
2-4 BRAKE
Inspect the following items.
^ Drive plate facing for wear and damage
^ Discoloration of driven plate (Burnt color)
^ Snap ring for wear and spring retainer for deformation
^ Lip seal and D-ring for damage
^ Measure the total end play and adjust to within specifications.
ONE-WAY CLUTCH
^ Make sure the snap ring is not worn and the seal rings are not damaged.
^ Measure the total end play and adjust to within specifications.
LOW & REVERSE BRAKE
Check for the following.
^ Drive plate facing for wear or damage
^ Discoloration of driven plate (Burnt color)
^ Snap ring for wear and spring retainer for deformation