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1985-1998 [Subscribe to Daily Digest] |
[Profile/Gallery]
, Mon, 26 Aug 2002 23:19:46
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Paul.Harrison@basell.com
He didn't have great success. He says, "When putting the synchromesh units back together I got the sleeves in the wrong position in relation to the hubs so they would not slide fully onto the gears. The Saab manual says they only go back one way but is not clear how they should be lined up. At the time they fit back in 2 positions, I chose the wrong one. If there is a next time, I will mark the parts before removal so I get them back the right way."
He also said: "The Saab gearbox manual is very good, cost about £6 and shows all the special tools. I did not have any of these and struggled. I would not do the job without the manual.
The main tool needed is a 2 leg puller with arms extendable to about 300mm. I used some bits of bar with holes to extend it. This is used to pull off the gear case - remove end cover and 5th gears, etc, refit 2 bolts with large washers behind either side of output shaft, fit puller against output shaft and washers then pull off case. Make sure the reverse bearing bolt is removed in the middle of the case as well as other casing bolts and locating dowels knocked down. The casing is held on by the bearing on the casing end of the output shaft which is why the puller is needed against this shaft. Also the feet need to be thin to fit on the back of the 4th gear to later pull off one of the shaft bearings. This was very tight and also to refit.
Other tools include a heavy slide hammer and means of fastening to a drive shaft but only if it is needed to dismantle the differential - I did not do this since the parts of the bearings I could see looked ok.
Removing the shaft bearings, apart from input next to 4th gear, was done using a screwdriver and hammer to knock them off. To refit used old bearing shell and hammer.
A press would have been easier.
To remove the output shaft once the gears were removed, an old output shaft nut with washer was fitted, a puller arm placed under it end then hit with a hammer so that the shaft and bearing shell are knocked out of the clutch casing. When refitting, knock in with an old bearing shell/hammer but not too far since some end float needs to be left and then adjusted when fitting the 5th gear at the end of assembly. This is not clear in the manual since a special tool is used which would leave the end float.
Elastic bands were used to hold the 3/4th gear synchromesh together during refitting. Fitting synchromesh rollers is a struggle but possible with a thin screwdriver blade to hold the springs back.
A dial gauge is used to set the shaft end float and needs to be fastened by some sort of bracket to the cover end.
The bearings are standard ones and can be obtained from a bearing shop rather than Saab. "
posted by 206.175.1...
, Mon, 26 Aug 2002 23:19:46, Tue, 27 Aug 2002 23:52:24
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