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Input shaft

Input shaft

To dismantle



1. Mount the shaft in a vice with protective jaws.

2. Remove circlip.

3. Press the bearing off the shaft. Use puller 87 92 152 and basic tool 87 91 642 .


Important

A bearing which has been removed must not be refitted.


4. Lift off the pinion for 4th gear, synchromesh and needle bearing. Collect the leaf springs, if fitted.


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.


6. Lift off the synchromesh sleeve.

Important

Note the position of the sleeve. If it is to be refitted, it should be refitted facing the same way.


7. Keep springs and plungers.


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.

9. Lift off the 3rd synchromesh, pinion and needle bearing.


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.


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.

2. Fit the 3rd gear pinion with needle bearing, baulk ring and, if fitted, leaf springs.

3. Fit the synchromesh hub and make sure that the groove for the washer for the circlip faces up (in gearboxes with washer). Make sure that the hub goes down over the baulk ring. If necessary, press it down with sleeve 87 92 202 .


4. Fit the washer (if used) and a new circlip. Fit the circlip with the sharp edge facing up.

5. Check the end float between the 2nd and 3rd gear pinions. The play should be 0.05-0.40 mm.

6. Fit springs and plungers.


7. Fit the synchromesh sleeve.


Important

The high lugs on the sleeve should lie in the deep tooth gaps in the hub.


8. Fit the rollers. They are fitted by pressing in the springs. A small screwdriver can be used to press in the springs.


9. Fit the 4th baulk ring, leaf springs, needle bearing and pinion.


10. Check that the bearing faces the right way and press on a new bearing closest to the 4th gear pinion. Use the sleeve from puller 87 91 261 . Fit a new circlip with the chamfered edge facing up.


Important

Open the circlip carefully during assembly, only enough to allow it to be fitted to the shaft. Opening the circlip too far will damage it.


Carefully tap the circlip into the shaft groove using a drift.

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.