PRE-RELEASE

Output shaft

/ 9-5 (9600) / 2003 / 4. Transmission / Manual gearbox / Adjustment/replacement / Output shaft

Output shaft

Dismantling/assembling 1st/2nd gear synchromesh assembly

To dismantle

When dismantling, position assembly fixture 87 92 103 Assembly fixture, 1 over the gear wheels to hold together the synchromesh assembly.

Clip off the cable ties and release the assembly fixture from the synchromesh assembly.

Lift off the gear wheel for 2nd gear with bearing sleeve. Mark the wheel so that it can be fitted facing the same way.

Lift away the synchromesh assembly.

Detach the retaining spring from the "beans". Lift out the sleeve and place the beans in a safe place.

Lift out and turn the synchromesh hub. Mark this too so that it is turned the right way on assembly. Remove the retaining spring from underneath.

Remove the 1st synchromesh from the gear wheel.

Check the condition of all parts as regards wear. Replace damaged or defective parts. Measure the wear on the trisected synchromeshes by fitting them in their respective places. Measure with a feeler gauge in three places between the large baulk ring and the carriage wheel. Calculate an average of the readings. New synchromesh 1.4-1.5 mm.

If the average value is less than 0.8 mm, the synchromesh should be replaced.

Important
Do not mix up synchromesh components. The parts should be fitted in their original positions.

To assemble

The fit all components oiled with Saab manual gearbox oil. See List of lubricants and sealants .

Assemble and fit the 1st synchromesh to the 1st gear wheel.

Place the synchromesh hub in the sleeve. Place the sleeve with the fork groove facing down.

Important
The recesses for the beans in the sleeve should be against the recesses in the synchromesh hub.

Position and fit the 3 beans. Fit the retaining ring clockwise. Carefully turn over and fit the retaining spring on the underside clockwise.

Important
The retaining springs on both top and bottom should hook into the same bean.

Place the synchromesh sleeve (the side with the fork groove facing down) and the synchromesh hub on the 1st synchromesh. The recesses in the synchromesh hub should fit over the lugs in the synchromesh.

Assemble and fit the 2nd synchromesh to the 2nd gear wheel. Fit the bearing sleeve in the 2nd gear wheel and fit the entire assembly in the synchromesh sleeve and synchromesh hub. The lugs on the baulk ring should fit the recesses in the synchromesh hub.