ASSEMBLY
| ASSEMBLY |
| HIGH 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 in)
Limit thickness:
1.5 mm (0.059 in)
|
(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 No. | Thickness mm (in) |
|
32006504
|
4.7
(0.185)
|
|
32006505
|
4.8
(0.189)
|
|
32006506
|
4.9
(0.193)
|
|
32006507
|
5.0
(0.197)
|
|
32006500
|
5.1
(0.201)
|
|
32006501
|
5.2
(0.205)
|
|
32006502
|
5.3
(0.209)
|
|
32006503
|
5.4
(0.213)
|
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 lb).
|
|
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 lb) − Z
N: Value indicated on push/pull gauge
250 N (25.5 kgf, 56.2 lb): 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 specitication.
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 in)
Limit thickness:
2.6 mm (0.102 in)
| High clutch retaining plate | |
| Part number | Thickness mm (in) |
|
32006500
|
5.1
(0.201)
|
|
32006501
|
5.2
(0.205)
|
|
32006502
|
5.3
(0.209)
|
|
32006503
|
5.4
(0.213)
|
|
32006504
|
5.5
(0.217)
|
|
32006505
|
5.6
(0.220)
|
|
32006506
|
5.7
(0.224)
|
|
32006507
|
5.8
(0.228)
|
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 in)
Limit thickness:
1.2 mm (0.047 in)
|
(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 | |
| Part No. | Thickness mm (in) |
|
32006513
|
4.0
(0.157)
|
|
32006514
|
4.2
(0.165)
|
|
32006515
|
4.4
(0.173)
|
|
32006516
|
4.6
(0.181)
|
|
32006517
|
4.8
(0.189)
|
|
32006518
|
5.0
(0.197)
|
|
32006519
|
5.2
(0.205)
|
|
32006520
|
5.4
(0.213)
|
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 lb).
|
|
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 lb) − Z
N: Value indicated on push/pull gauge
150 N (15.3 kgf, 33.7 lb): 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 in)
Limit thickness:
1.6 mm (0.063 in)
| Reverse clutch retaining plate | |
| Part number | Thickness mm (in) |
|
32006513
|
4.0
(0.157)
|
|
32006514
|
4.2
(0.165)
|
|
32006515
|
4.4
(0.173)
|
|
32006516
|
4.6
(0.181)
|
|
32006517
|
4.8
(0.189)
|
|
32006518
|
5.0
(0.197)
|
|
32006519
|
5.2
(0.205)
|
|
32006520
|
5.4
(0.213)
|
| 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 in)
Limit thickness:
1.6 mm (0.063 in)
|
(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.
If it exceeds the service limit, replace the drive plate with a new one and adjust it to the specification.
|
Available retaining plate
|
|
|
Part
No.
|
Thickness
mm (in)
|
|
32006508
|
3.8
(0.150)
|
|
32006509
|
4.0
(0.157)
|
|
32006510
|
4.2
(0.165)
|
|
32006511
|
4.4
(0.173)
|
|
32006512
|
4.6
(0.181)
|
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
|
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