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 pinion for 4th gear, synchromesh and needle bearing. Collect the leaf springs, if fitted.
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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 circlip and, if fitted, the washer (only present on more recent gearboxes) holding the synchromesh hub in place. Remove the hub and collect the leaf springs, if fitted.
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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 |
Fit all the parts oiled with Saab synthetic manual gearbox oil, see .
1. |
Mount the input shaft in a vice with protective jaws.
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2. |
Fit the 3rd gear pinion with needle bearing, baulk ring and, if fitted, leaf springs.
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4. |
Fit the washer (if used) and a new circlip. Fit the circlip with the sharp edge facing up.
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5. |
Check the end float between the 2nd and 3rd gear pinions. The play should be 0.05-0.40 mm.
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6. |
Fit springs and plungers.
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7. |
Fit the synchromesh sleeve.
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8. |
Fit the rollers. They are fitted by pressing in the springs. A small screwdriver can be used 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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