SAAB WIS ONLINE

ASSEMBLY

ASSEMBLY

Install the sleeve & hub assembly by matching alignment marks.

Note

Use a new gear & hub assembly, if gear or hub have been replaced.



(A)

1st gear side

(B)

2nd gear side

(C)

Flush surface

(D)

Stepped surface



Install the washer, snap ring and sub gear to 1st driven gear. (Saab 9-2X 2.5i Linear)

Install the 1st driven gear, 1st baulk ring, gear & hub assembly onto driven shaft. (Saab 9-2X 2.5i Linear)


(A)

1st driven gear

(B)

1st baulk ring

(C)

Gear and hub ASSY

(D)

2nd gear bushing



Install the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring, gear and hub assembly onto driven shaft. (Saab 9-2X 2.0T Aero)


(A)

1st driven gear

(B)

Inner baulk ring

(C)

Synchro cone

(D)

Outer baulk ring



Note
• Take care to install the gear & hub assembly in proper direction.

• Align the baulk ring and gear & hub assembly with key groove.


Install the 2nd driven gear bushing onto driven shaft using ST1, ST2 and press.

Note
• Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

• Attach a cloth to the end of driven shaft to prevent damage.

• When press fitting, align the oil holes of shaft and bush.


ST1 32005131 INSTALLER

ST2 32005134 INSTALLER


Install the 2nd driven gear, inner baulk ring, synchro cone, outer baulk ring and insert onto driven shaft.


(A)

2nd driven gear

(B)

Inner baulk ring

(C)

Synchro cone

(D)

Outer baulk ring



After installing the key on driven shaft, install the 3rd-4th driven gear using ST and press.

Note
• Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

• Align the groove in baulk ring with insert.


ST 32005131 INSTALLER


Install a set of roller bearings onto the driven shaft using ST and press.

Note

Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).


ST 32005131 INSTALLER


Position the woodruff key in groove on the rear of driven shaft. Install the 5th driven gear onto driven shaft using ST and press.

Note

Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).


ST 32005131 INSTALLER


Install the lock washer. Install the lock nut and tighten to the specified torque using ST.

ST 32005168 SOCKET WRENCH (50)

Tightening torque:

260 Nm (26.5 kgf-m, 191.7 ft-lb)


Note
• Stake the lock nut at two points.

• Using the spring balancer, check that starting torque of roller bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf, 0.02 to 0.33 ft).



Install the roller bearing onto drive pinion.

Note

When installing the roller bearing, note its directions (front and rear) because the knock pin hole in outer race is offset.



(A)

Roller bearing

(B)

Knock pin hole



Install the washer using ST1, ST2 and press.

ST1 32005130 BUSH 1-2 INSTALLER

ST2 32005131 INSTALLER


(A)

Washer



Install the thrust bearing and needle bearing. Install the driven shaft assembly.


Install the drive pinion collar, needle bearing, adjusting washer No. 2, thrust bearing, adjusting washer No. 1 and differential bevel gear sleeve in this order.

Note

Be careful because the spacer must be installed in proper direction.



(A)

Driven shaft

(B)

Drive shaft

(C)

Drive pinion collar

(D)

Needle bearing (25 × 30 × 20)

(E)

Washer No. 2 (25 × 36 × 4)

(F)

Thrust bearing (25 × 37.5 × 3)

(G)

Washer No. 1 (25 × 36 × t)

(H)

Differential bevel gear sleeve



Adjust the thrust bearing preload.