Input shaft
Input shaft |
1. |
Mount the shaft in a vice with protective jaws.
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2. |
Remove circlip.
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3. |
Press the bearing off the shaft. Use puller 87 92 152
and basic tool 87 91 642.
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4. |
Lift off the 4th pinion, synchromesh and needle bearing. Keep the leaf springs in a safe place.
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5. |
Slightly lift the synchromesh sleeve and hold with your hand so that the spring-loaded rollers do not come out. Keep the rollers in a safe place.
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6. |
Lift off the synchromesh sleeve.
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7. |
Keep springs and plungers.
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8. |
Remove the washer and circlip which secure the synchromesh hub. Remove the hub and keep the leaf springs.
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9. |
Lift off the 3rd synchromesh, pinion and needle bearing.
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10. |
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 between the baulk ring and the pinion. Calculate an average of the readings. New synchromesh 0.8-1.1 mm. Min dimension is 0.5 mm. If the dimension is less, the synchromesh is worn out and must be replaced.
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To assemble |
All parts are fitted lubricated with Saab synthetic manual gearbox oil, see Technical data.
1. |
Mount the input shaft in a vice with protective jaws.
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2. |
Fit the 3rd pinion with needle bearing and baulk ring.
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4. |
Fit the washer and a new circlip.
Lock washer inner, sharp edges directed towards the circlip. |
5. |
Check the axial clearance between the 2nd and 3rd gear pinions. The clearance should be between 0.05-0.40 mm.
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6. |
Fit the springs and plungers.
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7. |
Fit the synchromesh sleeve.
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8. |
Fit the rollers. The rollers are fitted by pressing in the springs. For example, use a small screwdriver to press in the springs.
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9. |
Fit the 4th baulk ring, leaf springs, needle bearing and pinion.
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11. |
Check the play between bearing and 4th pinion to ensure that the input shaft is correctly fitted. Play should be 0.05-0.40 mm.
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Replacement of bearing closest to 1st gear pinion on input shaft |
To remove
1. |
Mount the shaft in a press with puller ring 87 91 121
and fixture (parent tool 87 90 636).
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2. |
Press the bearing off the shaft.
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To fit
1. |
Fit a new bearing. Make sure that the bearing faces the correct way. Press the bearing until it stops with the sleeve from puller 87 91 261.
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Checking 5th gear baulk ring |
1. |
Check synchromesh wear by placing it on the 5th pinion. Use a feeler gauge to measure at three points and calculate an average. If the average value is less than 0.5 mm, the synchromesh should be replaced.
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