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Input shaft

Input shaft

To dismantle



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

2. Remove the circlip.

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


Important

A bearing which has been removed must not be refitted.


4. Lift off the 4th pinion, synchromesh and needle bearing. Keep the leaf springs in a safe place.


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 washer and circlip which secure the synchromesh hub. Remove the hub and keep the leaf springs.

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


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


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

2. Fit the 3rd pinion with needle bearing and baulk ring.

3. Fit the synchromesh hub and make sure that the recess for the locking ring washer is facing up. Make sure that the hub goes down over the baulk ring, fit the leaf springs. If needed, press with sleeve 87 91 121 Puller ring, 13 teeth or 87 92 830 Puller ring, 12-gear manual transmission


4. Fit the washer and a new circlip.

The side of the lock washer that is dimpled is to be fitted facing the hub.

5. Check the axial clearance between the 2nd and 3rd gear pinions. The clearance should be between 0.05-0.40 mm.

6. Fit the 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. The rollers are fitted by pressing in the springs. For example, use a small screwdriver to press in the springs.


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


10. Check that the bearing is turned 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 bevelled 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.



Replacement of bearing closest to 1st gear pinion on input shaft

To remove


1. Mount the shaft in a press with puller ring 87 91 121 and fixture (parent tool 87 90 636).


2. Press the bearing off the shaft.


To fit



1. Fit a new bearing. Make sure that the bearing faces the correct way. Press the bearing until it stops with the sleeve from puller 87 91 261.

Important

When placing the shaft in a press, take care not to damage its surfaces.



Checking 5th gear baulk ring



1. Check synchromesh wear by placing it on the 5th pinion. Use a feeler gauge to measure at three points and calculate an average. If the average value is less than 0.5 mm, the synchromesh should be replaced.