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Reverse gear

Reverse gear

To dismantle



1. Place the reverse gear in 87 90 487 Sleeve, differential bearing .

2. Carefully tap the reverse gear out of its support using a drift.

Important

Ensure that the washer is not pressed off the shaft.


3. Lift off the bearing support, bearing washer, reverse gear pinion, synchromesh sleeve, baulk ring, wire ring, reverse gear wheel and needle bearing from the reverse gear.


4. Check the condition of all parts as regards wear. Replace damaged or defective parts. Measure the wear on the synchromesh by fitting it in place. Measure with a feeler gauge in three places and calculate an average of the readings. If the dimension is less than 0.5 mm the synchromesh must be replaced.


To assemble


Oil all parts with Saab synthetic manual gearbox oil before mounting. See List of lubricants and sealants


1. Place the reverse shaft in a 17 mm sleeve so that the lower support washer does not become detached from the shaft.

2. Fit the needle bearing and reverse gear wheel to the shaft.

3. Fit the baulk ring. Check that the wire ring is fitted to the baulk ring.

4. Fit the synchromesh sleeve.

5. Fit the reverse pinion with integrated synchromesh hub.


Important

The synchromesh hub's 3 recesses should fit over the 3 lugs on the baulk ring.


6. Fit the bearing washer. Check that the washer's tag is between the lugs on the reverse shaft support.


7.
Note

Always use a new reverse shaft support to ensure a press fit.


Apply Loctite 648 sparingly to the shaft hole on the reverse shaft support. See List of lubricants and sealants

8. Press on the reverse shaft support as illustrated (the holes should be aligned). Use a 17 mm sleeve and press on fully.

Important

The reverse shaft support's screw hole must be on the opposite side from the shaft's lube hole.


9. Screw the reverse shaft into the clutch housing as this will ensure the correct position for measuring play.

Tightening torque 24 Nm (18 lbf ft)

10. Check that the reverse gear is correctly assembled by measuring using a feeler gauge. Measure between the upper pinion and the thrust washer at the reverse shaft support. Play should be 0.10-0.20 mm.


11. Try shifting the reverse gear by pushing the synchromesh sleeve up and down.