SAAB WIS ONLINE

ASSEMBLY

ASSEMBLY

Assemble each sleeve & hub assembly.

Note

Position the open ends of spring 120° apart.



(A)

3rd-4th hub ASSY

(B)

3rd gear side

(C)

5th-Rev hub ASSY

(D)

5th gear side



Install the 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve & hub assembly for 3rd needle bearing on transmission main shaft.

Note

Align the groove in baulk ring with shifting insert.



(A)

3rd needle bearing

(B)

3rd drive gear

(C)

Inner baulk ring

(D)

Synchro cone

(E)

Outer baulk ring

(F)

Sleeve and hub ASSY



Install the 4th needle bearing race onto transmission main shaft using ST1, ST2 and a press.

Note

Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).


ST1 32005176 REMOVER

ST2 32005159 RACE 4-5 INSTALLER


(A)

4th needle bearing race



Install the baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to transmission main shaft.

Note

Align the baulk ring and gear & hub assembly with key groove.



(A)

Groove

(B)

4th gear side



Drive the ball bearing onto the rear section of transmission main shaft using ST1, ST2 and a press.

Note

Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).


ST1 32005176 REMOVER

ST2 32005159 RACE 4-5 INSTALLER


Using the ST1 and ST2, install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft.

Note
• Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

• Face the thrust washer in correct direction.


ST1 32005176 REMOVER

ST2 32005159 RACE 4-5 INSTALLER


(A)

Face this surface to 5th gear side.



Install the bearing onto synchro cone.

Install the baulk ring and synchro cone onto 5th-Rev sleeve & hub assembly using ST and a press.

Note
• Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

• Use a new ball bearing.

• After press fitting, make sure the synchro cone rotates freely.


ST 32005147 INSTALLER


(A)

Baulk ring

(B)

Synchro cone

(C)

Ball bearing



Install the synchro cone stopper and snap ring to 5th-Rev sleeve & hub assembly.


(A)

Synchro cone stopper

(B)

Snap ring



Install the rest parts to the rear section of transmission main shaft.

Note

Align the groove in baulk ring with shifting insert.



(A)

Needle bearing

(B)

5th drive gear

(C)

Baulk ring

(D)

5th-Rev sleeve & hub ASSY

(E)

Lock washer

(F)

Lock nuts



Tighten the lock nuts to the specified torque using ST1 and ST2.

Note

Secure the lock nuts in two places after tightening.


ST1 32005166 SOCKET WRENCH

ST2 32005119 TRANSMISSION HOLDER

Tightening torque:

120 Nm (12.2 kgf-m, 88.5 ft-lb)