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Reverse gear

Reverse gear

To dismantle



1. Position 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


All parts must be lubricated with Saab synthetic manual gearbox oil, see Technical data before fitting.


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.

Note

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



7. Sparingly apply Loctite 648 in the shaft hole on the reverse shaft support. Always use a new reverse shaft support to ensure a good press fit.

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. Secure the reverse shaft by screwing it in the clutch housing.

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.