SAAB WIS ONLINE

INSTALLATION

INSTALLATION

Wipe off grease, oil and dust on the mating surfaces of transmission cases with white gasoline.

Install the front differential assembly.

Install the main shaft assembly.

Install the transmission case knock pin into needle bearing knock pin hole.

Install the drive pinion shaft assembly.

Install the transmission case knock pin into roller bearing knock pin hole.

Apply liquid gasket, and then put the case right side and left side together.

Liquid gasket:

THREE BOND 1215 (Part No. 32005013) or equivalent

Tighten the seventeen bolts with bracket, clip, etc. as shown in the figure.

Note
• Insert the bolts from bottom and tighten the nuts at top.

• Put the cases together so that drive pinion shim and input shaft holder shim are not caught up in between.

• Confirm that the speedometer gear is meshed.


Tightening torque:

8 mm bolt

25 Nm (2.5 kgf-m, 18.1 ft-lb)

★ 10 mm bolt

39 Nm (4.0 kgf-m, 28.9 ft-lb)


Tighten the ball bearing attachment bolts.

Tightening torque:

29 Nm (3.0 kgf-m, 21.7 ft-lb)


Backlash adjustment of hypoid gear and preload adjustment of roller bearing:

Note

Support the drive pinion assembly with ST.


ST 32005100 STOPPER


Place the transmission with case left side facing downward and put ST1 on bearing cup.

Screw the retainer assembly into left case from the bottom using ST2. Fit the ST3 on transmission main shaft. Shift the gear into 4th or 5th and turn the shaft several times. Screw in the retainer while turning ST3 until a slight resistance is felt on ST2.

This is the contact point of hypoid gear and drive pinion shaft. Repeat the above sequence several times to ensure the contact point.

ST1 32005081 WEIGHT

ST2 32005023 WRENCH ASSY

ST3 32005161 HANDLE


Remove the weight and screw in the retainer without O-ring on upper side and stop at the point where slight resistance is felt.

Note

At this point, the backlash between hypoid gear and drive pinion shaft is zero.


ST 32005023 WRENCH ASSY


Fit the lock plate. Loosen the retainer on the lower side by 1-1/2 notches of lock plate and turn in the retainer on upper side by the same amount in order to obtain the backlash.

Note

The notch on the lock plate moves by 1/2 notch if the plate is turned upside down.


Turn in the retainer on the upper side additionally by 1 notch in order to apply preload on taper roller bearing.

Tighten temporarily both the upper and lower lock plates and mark both holder and lock plate for later readjustment.

Turn the transmission main shaft several times while tapping around the retainer lightly with plastic hammer.

Inspect and adjust the backlash and tooth contact of hypoid gear.

After checking the tooth contact of hypoid gears, remove the lock plate. Then loosen the retainer until the O-ring groove appears. Fit the O-ring into groove and tighten the retainer into the position where retainer has been tightened in.

Tighten the lock plate.

Note

Carry out this job on both upper and lower retainers.


Tightening torque:

T: 24.5 Nm (2.5 kgf-m, 18.1 ft-lb)


Selection of main shaft rear plate

Install the clutch release lever and bearing.

Install the transfer case with extension case assembly.

Install the manual transmission assembly into the vehicle.