7/23/2019 Saab 900 5 Speed

1/63

tlC11tUSA

l

nc

bOnvt PO

Bo Af f 7

0 -477

8 /9

aab

ech

nical

ra ining

S

9

5S

PEED

7/23/2019 Saab 900 5 Speed

2/63

9

5

Spe

ed

F

orew

ord

TheIn formation In this b

ook s

Intended

to supp

lement

ra

ther tha

n rep lace

the se

rv ice m a

nual. Th

e m anu

als

are

constan

tly

upd

ate

d as

ch

angesa

re

m

ade

to the

tr

ansm is s

io n and

sho u ld

be co

ns idere

d the f

inal

autho

rity.

As a oo

nveoleo

ce weh

ave lis t

ed part

number

s

for

shim s

,

sy

nclvos

nd

a fewothe

f co

mponen

ts . This

In

form atio

n s aC

CU ate

as of sp

r ing 19

90

b

ut

may

ch

ange a tany

ime w

hen In do

lbt chec

k he

p

arts f ich

e

a

nd S .I. b

ooks.

M any

of the

o

perat ion

s In th is b

ook ca l

l for you

to m ke

a judgement as to w he ther

or

not a part shou ld

be

re use

d . We h

ave pro

v ideda s

m ny gu

ide lin e

s as

we

can

to help

youm

kethese

dec is i

ons

b

ut I

n Iha end

II ls

your

expe ri e

nce tha

t wi l l be

l

h

e de

term ining

fac to r

.

S o m e p

arts (p i

n io n bea

rings for

exam

ple) sh

ould

a lw

ays be r

ep lac ed

b

ut th er

e are m

nyothe

rs such

as

gears

and synclv

o

compon

ents th

at are

of ten

nee

dless ly r

ep laced

ust In

case

. F

inding and

fixin

g

ha re al

cause of

the pro

b lem w i

ll

low

er cos

ts, re

duce

come

backs

nd give

youth

e sat isfa

ction o f

knowin

g

y

ou are a

technic

ia n , not

just a pa

rts ch

anger

7/23/2019 Saab 900 5 Speed

3/63

9 5 Speed

Transmission Identification

l.D. Tag

All transmissions carry an Identification tag on the

top

of the primary housing. Th is plate shows the

transmission type and

seri

al numbers. The type code

shown below or 1984 and later ca rs (see shop manual

for older models) allows you to match the transmission

to the appropriate parts listing ln the microfiche and

determine gear ratios and proper application without

having

to

open up the

bo

x.

Transmlulon type

nu

mbers,

1984 models onwards

GM

=

Manual tmsm

iS1lio

n

GA

Au1omatic

transmiS1llon

Transm ission version

Number of forward

geam

3 = 3-speed

4 = 4-speed

5

=

5 speed

Primary gear ratio

see table)

Variant

Anti Theft Marking

Beginning with the 1987 model year all major compo

nents and body parts carry an anti-theft marking label

Thi s label

is

he subject

of

a

two page

Service Informa

tion 08/86- 872, Section A-0, Page 21. Found In Sup

plement 6-A.

The central theme

ofthis bulletin is that he labels must

not

be

removed

or

defaced In any

way

even when In

stalling the component In a vehi

cle

wi

th

a different

N. number.

.

7 7 2 3 6

z

Gear ratio number

Primary gear Manual

4

5 6

7

a

Number of

teeth

31/30 30/27 31126

32125

33/24

inpuVoulput gear

Gear

ratio

097

0

90

0 84

0.78

0.

72

SAAB 693n91 SAAB 693n91 SAAB

6937791

6937791

SAAB

6937791

SAAB

693n91 9 Wl l

SAAB

6937 Y S 3 A R 3 5 J 1 H 2 2 3 9 7 937791

a

6937791

SAAB

6937791

SAAB

6937791 8 1Wll

SPi. '8

6937791

SAAB

593ns1

SAAB 693n91

2

7/23/2019 Saab 900 5 Speed

4/63

9 5 Speed

Specifications

Lubricants

Transmission Fluid - Engine oil 10W30or10W40,

3 U.S.

qt.

lternate

Gear

oil

SAE EP 75 API GL4 or GL5

Saab part no. 99 00 754

(5

gallons)

Inner U joint grease - Saab

:J

grease

Saab part no. 02 70 025

7

12 lb can).

Torques

All 8mm Case Bolts 15-18 ft l

bs

Slave Cylinder Bolts . . . . . . . . . 4- 1O

8mm Ring Gear Bolts . . . . . .. . . . 37

10mm Ring Gear Bolts 66

Lower Chain Sprocket Nut,

32mm Hex

.,

.

67 -

81

Forward Pinion Shafi Nut,

24mm Hex 37

Bearing Preloads

New Pinion Bearings

Used Pinion Brgs. (Over 1,200 Miles)

New Differential Bearings

Used Differential Brgs.

(Over 1 200 Miles)

Using Spring Scale and

Str

ing

(KGF=KG=

KP)

18- 27 In lbs

7- 16 In

lbs

16- 24 In l

bs

7- 11 in lbs

3

. 4.7- 7.0 KGF

. 1.9-4.3

KGF

.

8- 28 KGFCM

. 8- 3

KGFCM

Using Torque Wrench

(KGFCM=KGCM)

7/23/2019 Saab 900 5 Speed

5/63

900 5 Speed

Specifications

Sealants/Locking Fluid

Many

of

the bolts in the transmission are precoated

with thread sealant or

loc

king fluid. The shop manual

draws your attention

to

these bolts with the picture

shown

to

the right. The accompanying bolt length chart

also highlights the coated

bo

l

ts

. Failure

to

recoat

these bolts with the proper compound when rebuilding

can result In leakage

of ge r

oil

or

major mechani

c

l

failures.

Locking Fluids

Loctite 270 Red)

Pinion bearing nut

Lower chain sprocket nut

Forward pinion sllaft nut

Loctite

4

Blue)

ing gear

bo

lts

Torx

head

bolls

for the stamped steel

primary

c se

bearing retainer

Cluster gear and reverse Id

ler

shaft retaining plate bolt

Reverse

id

ler actuating arm pivot bo lt

Reverse selector shaft retaining bolt (ol

der

models before roll pin)

Pinion housi

ng

bolts

All other bolts calling for Locking Fluid In

the

shop manual

7/23/2019 Saab 900 5 Speed

6/63

9 5 Speed

Specifications

Sealants

1

Loctite ~

Gasket el iminator)

Main case to primary housing surface

Permatex Aviation

wo chain tensioner bo lts

uvo

upper alien not torx) head primary case bearing retainer bolts

l elve differential bearing side cover bolts

Three slave cy linder mounting bolts

Six engine to gearbox

bo

lts with tapped holes drilled through Into the

transmission section

of

the malncase

High Temperature Silicon

Slotted

po

rtion

of

engine sump gasket - DO NOT

use on the solid portion

of

the steel gasket, It Is

precoated at he factory.

7/23/2019 Saab 900 5 Speed

7/63

9

5 S

peed

Spec

ial To

ols

T

ransmis

sionHold

ingFoctu

re

839

0400

S

uspens

ionBloc

k

83

93 2 9

C

lutch R

emova

l

Le

ver

8393

1

75

6

A

Engine

L

in ing S

ling

83

92409

Pressur

e Plate S

pacer Ring

83

9 23

small

diameter

87

91 6

18

large

diame

ter)

Up

per Chain

Sproc

ket Pull

er

87

9

89

1

7/23/2019 Saab 900 5 Speed

8/63

9 5 Speed

Special Tools

=

t Q(\()ry

.

Input Shaft Puller

87

9 917

Layshaft Puller

83

9

049

Pinion Shatt Press

87 9 511

7

Sli

e

Hammer

83

9 27

Differential Si

e

Cover Pu ier

879 n6

Q . _ _ < ~ - ~ ~ . . : : : _ >

O _ _

Pinion Shatt Press Spacers 4)

87 9 9 9

7/23/2019 Saab 900 5 Speed

9/63

9

5 S

pee

d

Speci

al

oo

ls

Pinio

n D epth

G auge

83

9 155

D ia

l Ind icat

or Hold

er

879

727

Differen

tial ea

ring Pre

loadTo o

l

8

7 9 81

8

D

ial Indica

tor

78 4 6

22

Spr ing S

ca le

8 9

13

Stack H

eight G

auge

879

552

7/23/2019 Saab 900 5 Speed

10/63

9 5 Speed

Special

ools

Pinion Shaft Ho lder

83

90

064

Pinion Nut Wrench

87 90

45

I : ; \

Pinion Bearing Installation Tool

87 90

925 -

88

87 91

972 89- )

Pinion Holding Fixture

87 90 636

9:33 Pini

on

Fixture Insert

87

91

097

9:35 Pinion Fixture Insert

87 90

651

Input Shaft Bearing Puller

8 )0 )33

Shaded area shows

shop modifica

tion for M89 transmission)

9

7/23/2019 Saab 900 5 Speed

11/63

9

5

Sp

ee

d

S

pec

ial

ools

Reve

rse

ear

L

ock

879

5 3

Se

lec to r

Shat

tSea

lI

st lle r

879

685

lmer

Dr

iver S

eal In

stal le

r

8

79 8

1

Se

lecto

r Sha

f i Sea

l Rem

over

87

9

o

n

Dri

Beari

ng I

nsta llat

io

n

83

9 18

9

Inpu

t Sha

l l Bea

ring

Drif l

7

8

4

7

5

7/23/2019 Saab 900 5 Speed

12/63

9 5 Speed

Special ools

Inner Driver Support Beari

ng

Drift

78

4 4

Pini

on

Shafi Drift

83

9

148

Dlfferemlal Bearing Race

Dr

ift

839 114

Inner Driver Installation Drift

78

4

67

Input Shafi Housing Support

Pinion Bearing Housing Support

83

9 98

Pinion Bearing Race Drift

87

9

46

7/23/2019 Saab 900 5 Speed

13/63

9 5 Speed

Special

ools

Differential Bearing Race Drift

879 487

Input Shafi Bearing Race Drift

83

9

312

Upper Sprocket Bearing Driver

87

9 859

2

Clut

ch

Seal D

ri

ver

83

9

997

Pinion Bearing Race Remover

83

90 106 - 88)

87

9

964 89- )

Pinion Housing Guide Pi

ns

87 90 438

7/23/2019 Saab 900 5 Speed

14/63

9

5

Spee

d

pe

cial

ools

Sele

ctor Hou

s ing Nu

t Socket

87

90370

0 1

r

~

199 0 S

elector

Shaft Lock

87 9

998

13

c::

:::::::;:

:

v

1

986 1 2

1989

Selecto

rShaft L

ock

87 9

576

7/23/2019 Saab 900 5 Speed

15/63

9

5S

pee

d

Gearb

ox De

scrip

tion

The 9

00 5 s

peed tr

an smiss

ion

Is de signe

d and

produ

cedby S

aab. No

table fea

tures o

f thisdes

ignare

the

cha in p

rimary d

riv e an

d bac

kw ards

en gine

plac

em ent.

e chain

drive m

ak es

t

p

ossible

to eas l y

alter d

riverati

os witho

ut chang

ingthe

ringa nd

p inion

and

the unu

sual en

gine or i

entation

pe rmits

you to

quic

kly chan

ge the c

lutch w i

thout re

mov ing

either the

eng

ine or t

ransmis

sion. Th

e mainc

ase ca s

tingform

s

the e

ng ine c

rankcas

e but en

gine an

d gear o

ils are

sepa

rate.

14

7/23/2019 Saab 900 5 Speed

16/63

9

5

S

pe

ed

a

ske

tsa

nd

Sea

ling

Su

rfac

es

G

SK

ETS

The front,rear and s ide co vers are se a l

e

with gaskets

.

N o

addit

ional

gaske

tcom

poun

d i

s neces

sary.

M

ETA

L T

O M

ETA

L

Th

ejoin

tbetw

een t

he m a

lnca

se

ndprim

ary hO

uslng

is

a m

etal

to me

tal flt.

Use

of a g

asket

woul

dalte

r Inter

nal

c le

aranc

es.

The

surfa

ces

mus t

'e

c lea

n an

d

unda

mag e

d.

Use

Loct

ite

5

s .

an

ana e

rob ic

com p

ound

,no

t blue

goo.

B

OLT

TH

REA

DS

A

llbol t

swith

ho le

sdri l l

ed Int

othe t

ransm

issio

npo r

tion

o

f

t

he ca

se m

ust

betrea

ted w

ith P

erm a

tex A

viatio

n

Gas

ket C

ompo

und

not

neede

d on

new

pret

reated

bolts)

.

5

7/23/2019 Saab 900 5 Speed

17/63

900

5 Sp

eed

Con

struct

ion

Shaf

ts and

Gea

rs

Po

wer

Is

t

ra nsmitt

ed

t lvoug

h

th t

ransmis

sion via

th

f

ol lowing

shafts a

nd ge a

rs .

A.

Clutch

shaft; sp

lined to

the upp

er prim

ary chain

sprocket, eas ily removable fo r clutchwork .

B .

Input

sh aft; sp

lined to

the lo

w er

p

ri

mary ch

ain

sp

ro cket. F

ifth gea r

actua ll

ythe clu

ster sha

ft

In

put

gea

r

Is

part of

th is shaf

t.

C . Pini

on shaft;

reverse

gear and

the syn

chro hu b

sare

s

plined to

this sh

aft. Firs

t, secon

d, third

and forth

gears

turn on

bushing

swh ic h

s l ip ove

rthe pi

n ion

h ft

.

Matched ears

Only

the ring

and pin

ion are

amatche

d set,

a ll other

s

m

yb

e re

placed I

nd ividua

ll y.

.

16

7/23/2019 Saab 900 5 Speed

18/63

90

0

5 S

p

ee

d

Co

ns

tru

ct

ion

C lu

st

er

G e

ar

C

lust

er

Gea

r

Als

o kn

ow

n as

co

unte

rsha

ft o

r lay

sha

ft . T

he c

lust

er

gea

rIs b

uil t

up o

ftw

ose

gme

nts.

The

Inp

ut or

fifth

gea

r

p

ort i

on I

s jo

in ed

to th e

ma

in s

ectio

n b

y a

sp l

ined

b

ush

ing

lo ck

ed I

npo

sitio

nw i

th a

sna

prin

g.

Re

ver

se

Id le

r

T

he

reve

rse

Id le r

is I

nco

nsta

nt m

esh

wit

hth

eclu

ste

r

a

nd a

cts

as

a br

id ge

be

tw ee

n th

e c

luste

r g

ear ai

: d-

rev

erse

ge

ar o

n th

e p i

nion

sha

ft. T

hes

e ar

e th

e on

ly

sli

din g

m

esh

ge

ars

in

th

e t

ra ns

mis

sion

an

d,

acc ord ingly,

th

first to be dam aged

by

abuse.

B

ea

ring

s

nd

Th

ru s

t W

as

her

s

Th

etra

nsm

issi

on u

ti lize

sta

per

ro lle

rbe

aring

s. s

tra ig

ht

lo o

se r

oller

s, b

a ll b

earin

gs .

nee

dle

bea r

ing s

,bu

shin

gs

and

me

ta l t

ome

tal

oil f

ilm)

des

ig ns

.

T

he

siz

e, d

esig

n

a

nd

ro lle

rco

unt

of th

ese

bea r

ings

ha

sch

ang e

da

sthe

tr

ans m

iss

ion

evol

ved_

A

lwa

ys

care

full

y c

omp

are

be

aring

n u

mbe

rs a

nd r

oller

cou

nts

whe

nre

build

ing

.

7

7/23/2019 Saab 900 5 Speed

19/63

9 5 Speed

Power Flow

5

An important parto analyzing transm ission

comp

laints

is

understand

i

ng

which components are Invo lved in

the

affected gear s). The following pages show the applied

gears and synchronizers

in each range.

.

I

Reverse

Idler

8

7/23/2019 Saab 900 5 Speed

20/63

~ 9

~

~ ~ S

~ p

o

wer

lo

w

irs tGear

Sec

ond

Ge

ar

9

7/23/2019 Saab 900 5 Speed

21/63

9

5 S

pee

d

Po

wer

Flo

w

T

hird G

ear

Fou

rth G e

ar

Rever

se

dle

r

2

7/23/2019 Saab 900 5 Speed

22/63

Po

wer

lo

w

if th Gear

Re

vers

e

5

4

2

Rev

ers

e

d

ler

7/23/2019 Saab 900 5 Speed

23/63

9 5 Speed

Synchronizer Construction

I

The synchronizer assembly has two basic

functions;

first to match

synchronize}

gear

speed

to pinion speed

and, once

th

is has occurred, lock the gear

to the

pinion

shaft.

Like many of the components in the transmiss ion there

are several variations of each of the parts shown

above, mostof which

are

close

enough

In appearance

to interchange. These differences are covered In detail

in the rebu ild guide portion of this book. Always check

part

numbers and identifying marks before Installing

replacement

parts. It can mean the difference between

a successful repa ir and a comeback.

A

/

Ah -

;jok gf d

S.4 . f

,or/11 ) \

v

D

I

/I

~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

22

7/23/2019 Saab 900 5 Speed

24/63

9

5

Spee

d

Sync

hroni

zer Op

erati

on

Neutral

The

synohro

sleeve

Iscenter

ed on th

ehu b .Th

esynch

ro

ring I

sIn con t

act w ith

its retai

ning ring

but no t

with the

taper

ed face of

the sl

eeve.

Parti

ally n

gaged

Th

e synch

ro slee

ve h

s m oved

sligh tly

to th

e

r

ig ht

to

wards th

egear. T

he sync

hro ring

IsIn con

ta ct with

the

slee

ve, th e

friction

creat

ed betw

een

these tw

o

comp

onents

starts to

synchr

onize g

ear and

pinion

shaft

sp eed. T

he amo

unt of f

rict io

n

Is

depen

dent on

spring t

ension,

oil visco

s i ty and

tempElf

ature, et

c,

F

ully n

gage

d

After th

esynch

ro ring h

as m at

ched th e

speed

of

th

e

g

ear to th

at

o

f th e

pinion s

haft th e

spl ines

on the I

D

o

f

t

heslee v

ebr idge

the splin

es on th

eO D. of

he hub

and

gea

r. These

splines

are wha

t takes t

he abuse

when t

he

synchro

Is we k

or som

eone m

isses a

shil l . n

ot the

a

ctual ge

ar teeth.

3

Ne

utral

P

artiall

y

ng

aged

Full

y

ngag

ed

7/23/2019 Saab 900 5 Speed

25/63

A

B

D

E

9 5 Speed

Selector Mechanism

D

ame

i

hi -

cf / "5 I J1- .r:J

(

The selector mechanism located inside the

transmission Is responsible for a number

o

functions.

In

addition to selecting gear ratios the mechanism

blocks the driver fr

om

simultaneously engaging two

gears, provides a simple synchronizer function for

reverse gear, helps lock the transmission into gear and,

In laterproduction, centers the sh ift lever in the selector

gate. The selectorshaft itself isnot adjustable but there

are both external adjustments shift console and

selector shaft coupling) and Internal tolerances stack

height) which are controllable and can greatly affect

shift quality and function.

-

Function

4

7/23/2019 Saab 900 5 Speed

26/63

9

5

Sp

eed

Lub

rica

tion

Oil S

pec

if ica

tion

O

nly tw

o bas

ic t yp

es of

ol ls

are sp eci fied forthisbox

en g

ine o

ll 10W

- 30

or 10

W -4 0

and7

5 w e

ight L

4o

r

L

5g

earo

il . ev

eru

se a

heavi

er oil

such

as am

ul ti

we

ig ht

ge ar

o il

both

shi

ft qu

ality

and

bea

rin91

lu

bricat

ion w

il l

suf

fer

p

articu

larlyi

n oold

wea

ther.

Oil

ev

el

Th

e prim

ary

ho us

ing h

as a

se rie

s of

oil co

llect

ion

de

vices

no t

the le

ast of

wtlic

h is

the ch

ainte

ns io

ne r.

In

ciden

tally

It Is po

ssib l

e to in

stall

the te

nsion

er ups

id e

down with the oollectlng cup on the bottom wtllch

m

ake s

trap

p ingo

il ra

ther d

lffiou

lt. Wh

en In

stal lin

g a

rebuil

t tran

sm iss

io n p

reflll

the p

rima

ry ho

using

wi th

ap

prox im

ate

ly on

e pin

t of o

il thro

ugh th

e In

pu t s

ha

f

t

c

overo

penin

g to I

nsure

good

lub ri

cation

and

tensio

ne r

a

ction

on st

art up

.

5

7/23/2019 Saab 900 5 Speed

27/63

9 5 Speed

Lubrication

O

il evel

There is a check

b

ll

loc

ted n the primary case whose

function

is

to prevent gravity from transferri

ng

all the oil

Into t

he pr

imary housi

ng

and starvi

ng

t

he

final drive

when on a steep

do

wngrade. This

is

a passive device

and requires

no

regular service. A similar function Is

perform

ed

by the single metal shield on the firewall

side

of

the ball beari

ng

supporting the p inion shaft

directly above the check

b

ll. Installi

ng

a bearing from

a jobber without this shield

or

reversi

ng

t

he be

ri

ng

wo

uld cause oil level

or

durability problems.

O

il

F

lo

w

The be rings bushings chains and gear surfaces are

lubricat

ed

by a

comb

ination

of

splash feed and gravity

flow through a series of co llecting troughs and drilled

passages.This Is n effective trouble free system. The

on

ly

common problem has been with technicians

failing to clean these passages during a rebuild and

recontaminating the gearbox.

.

6

7/23/2019 Saab 900 5 Speed

28/63

9

5

Spee

d

Pro

ductio

n His

tory

Ye

ar

Ident ify i

ng Cha

racteri s

t ics

M

ajo r Ch

anges, R

ebuild No

tes

1980

Sand

cast m

alncase.

n

o mou

nting

Cluster

gear and

thirdge

ar guid e

ring

b

osses

for the

turb o

exh

aust p

ipe m

odified

during t

he mod

el year

to

brac

ket.

preve

nt loss o

f third

gear s

ynchro

s

pring.

1981

Die cas

t malnca

se with

two mo

unting

Snap rin

g on for

ward en

d of pin

ion

bosses to r the turbo e

xh

aust p ipe shaft must be Installed w ith sha rp

br acke

t.

edges

facing f

orward .

1

982

Vi

sually th

e same

as 1981

, ch eck

the

l.D. pl

ate.

Ne

w ring a

nd p in io

n, 9:33

rathe

r than9

:35 (3.89

:1).

{3.67:1

Lar

ger rear

cluster g

ear bea

ring,

new

cluster g

ear.

Stro

nger det

ent sprin

g (reco

m-

mend

retrofittin

g to old

er boxe

s).

Snap

ring a t

front o f p

inions

haft re

placedwith a nut

do

not over-

tor

que nut)

.

19

83 19

84

Large d

ipstick ho

le for

combine

d oil Iii -

Cas tpin

ion bea

ring hou s

ing rep l

aced

e

r/dipstick

(reduc

er bushin

g availa

ble d

ie - ca s t

vers ion

, a ll d ie

- cast ho

us-

to ins

tall gear

box Inol

der cars

).

lngs

should b

e sc rap

ped.

Mo

d ified s

ynchro c

one an

gle, new

synch

ro sle ev

es.

Asy

mmetric

al synch

ro slee

ve teeth

on 2nd a

nd 3rd

gear.

N

ew

di fferentia

l assem

bly with r

oll pin

lo

ckingth

e cross

shaft in p

osition.

7

7/23/2019 Saab 900 5 Speed

29/63

9 5 Speed

Production History

Year Identifying Characteristics

ajor

Changes, Rebuild Notes

1985 Turbo models have a heavier Innerdriv-

Extended input shaft on turbo models

er

with corresponding changes to with support bearing In the front cover.

axles, bools and trunnion bearings.

The inner driver has

two

rather than

Input shafts, beari

ng

housi

ng

and

three external ribs.

spacers modified during the year to

reduce chain wear by offsetting the

lower sprocket.

Always verify that the transmission

hasthe correct inner drivers before in-

stallation.

1986 - 1988 Large Inner drivers phased

In

on non

Gearboxes with new selector mecha-

turbo models as running change during

nism must not be interchanged with

1986. Also changes to the Internal se- the older style.

If

you mix and match

lector mechanism identified by a modi- you could have a car with

two

shift le-

lied rear cover and

ho

le

n

selectorshaft

ver centering mechanisms fighting

for linkage adjustment tool. Modified each other, or non at all.

front cover for hydraulic front mount on

turbo.

1989

Strengthened, upgraded transmission.

All major internal components

No

major external differences, check

changed including ring and pinion

the

l.D.

plate.

9 :35 tooth count), larger rear p inion

bearing, upgraded cluster shaft bear-

ings, stronger gears, etc.

1990

Rear cover modified to accomodate a

New selector rod locking tool

transmission oil

flier.

new

boxy introduced to

lt

In the modified rear

shape.

cover.

8

7/23/2019 Saab 900 5 Speed

30/63

9

5 S

pee

d

e

asuri

ng

The

basic m

easurin

g tools

for th

e 900

man

ual

trans

mission

are

a di

al Indica

tor S

aab specia

l tool

no .

78

40 622)

, feeler

gauges

and ac

aliper or

microme

ter.

Th

ese should

all be m

etric, bo

th to elim

inate error

s

from

tr

anslatin

g specs

back a

nd forth

and bec

ause o

f the

much

greater

accurac

y In

herent In

the me tric

system

th

e

s

tandard

unit, 0

.01mm. is

less tha

n0.0005

Inch

,

1/2

o

f

th

e sta

ndard g

raduatio

n of the

English sys te

m).

The d ia

l Indicat

or show

n has

two hands .

The larg

er one

rec

ords mo

vement

in increm

ents of

one one

hundre

dth

of

a millim

eter

.Olmm,

the

shorter

on

e recor

ds

co

mpleter

evolutio

n of the

larger o

ne 1

gra

duation

1mm) .

Alwayss

et the d

ial indica

tor up

s

o that the

small

ha

nd Is no t

near the

end ofth

e scale

you ma

y

r

un ou

t of

me

ter mov

ement a

nd alwa

ys chec

k boths

cales yo

u

may set

a +5

pinion

at + 1.

05m

m If you

Ig

nore the

sma

ll scale

.

In

addition

to

making the

standard

back l

ash

and

pinion

d

eplh ch

ecks, th

e dia l

indicato

r may b

e used a

s a

substitu t

e for am

icrome

ter or ca

liper by

mountin

g It In

the

fixtur

e

fo

r measu

ring valv

e pallet

th ickn

ess.

9

7/23/2019 Saab 900 5 Speed

31/63

900 5 Speed

Teardown Checking Backlash

Anytime a ri

ng

and p inion has run more than 6,000

miles, a definite wear pattern

has

been established.

To

avoid changing the wear pattern and increasing final

drive noise, you mustcheck backlash and pinion depth

before stripping the box.

When checking backlash, observe the following steps:

1. Set the dial indicator so that the plunger is at right

angles to the ring gear tooth to insure a

tru

e

readi

ng

.

2. Measureat fourpo ints and average the readings.

There should

be

little variation maximum

0.0Smm) between readings. If it is greater

recheck, there may be dirt on a tooth

or

you may

have rocked the ring gear too hard and moved the

pinion.

3. When you remove the differen tial, tie strap

or

bolt

the shims to the side covers. These shims control

both backlash and carrier bearing preload, lose a

shim now and you

will

have to

bu

ild your shim

pack from scratch duri

ng

reassembly

Thickness Part Number

010 mm 83 41 604

0.15 mm 83 41 612

0.30 mm 83 41 620

0 50mm 83 41 638

3

. .

Stock Clearance, New Gears

0.17 0.05

mm

7/23/2019 Saab 900 5 Speed

32/63

9

00

5S

pe

ed

Te

ard

own

C

he

ckin

gP

inio

nD

ep

t

A

s then

ame

im pli es pin io ndep th s an In dic ation o fh e

de

pth o f

enga

gem e

nt be

tw een

th ep

inion

an dr

ing ge

ar.

L

ikeb

ackla

sh, th

is Is

a d im

ensio

n w h

ich af

fects

bo th

th en

oise l

evel a

nd du

ra b il

ity

o he ge

arset.

n

pra

ct ica

l

t

erm s

, p in io

n d e

pth Is

thed

ista nc

e fro m

the

ce nte

r l ine

o fth

e ring

gea

r to th

e fac

e

o

t

he p in

io n.

d

~

O

m m

ESIG

N SP

ECIF

IC AT

IO N

On

a Sa

ab th

e gea

rs ets

are

desig

ned

to run

quie

tly

w he

n th is

d im e

nsio n

Is 60

.00 m

m.

n th e rea

l w or

ld, du

e

to

n orm

a l p r

oduct

ion to

leran

ce s,

th is

Idea l

sett

ing

v

aries

from

se t

to se

t. Du

ring

its pr

oduc

tion e

ac h

m

atc he

d se

t o f g

ea rs

Is te

sted

to fin

d its

optim

um

settin

g and

a num

ber

show

ing th

at set

tingIs

et ch

ed

on

t

he p in

io nfa

ce a l

ongw

ith th

e l.D.

numb

er tha

t m at

ches

th ering g ear and p in io n .

3

7/23/2019 Saab 900 5 Speed

33/63

900 5 Speed

Teardown Checking Pinion Depth

Occasionally a gearset will run best at the design

setting

of

60

mm. That pinion

wil

l

be

marked meaning

no deviation from the standard setting .

This corresponds

to

the reading you wil l see when the

dial indicator has been zeroed on the p inion depth

gauge.

The next ring and pinion produced might run best when

the pinion moves away from the ring gear center lineby

0.05 mm. This means the measured distance has

increased

to

60.05 mm and the pinion face will

be

marked 5.

ou can simulate this dial indicator reading

by

slowly

lifting the pinion depth gauge off it's base plate until the

po inter moves 5 graduations from

O

Note that

s

you

increase distance the dial indicator moves counter

clockwise.

lus Pinion Settings Move The Dial Indicator

Counter Clockwise

' .

3

7/23/2019 Saab 900 5 Speed

34/63

9

5

S

p

ee

d

T

e

ard

o

wn

P

in

io

nD

e

pt

h

Ch

ec

k

s

The

th

ird

set

o

f

g

ea

rs c

he

cke

dm

ay

be

ha

ppi

est

wh

en

m

ove

d

c l

ose

r tog

eth

er

by

0.

10

mm

. T

he

me

asu

red

d

is t

anc

eh

as t

hus

be

en

dec

re a

se

dto

59

.90

mm

an

dth

e

p in

ion

fa

ce

will

be

ma

rke

d -

10

.

Y

ou

c

an

sim

ula

te

this

b

ys

lip p

in g

a

0.1

0

mm

sh

im

b

etw

een

th

ed

ia l

Ind

ica

to r

plu

nge

ran

d t

he

bas

e p

lat

e

o

f the

pin

ion

d

ept

h g

aug

e.

Th

is w

ill

m o

ve

the

d

ia l

in

dic

ato

r re

ad in

g

10 g

ra

dua

tion

s c

loc

kw

is e

fro

m0

.

M

inu

s P

in i

on

Se

ttin

gs

o

ve

T

he

D

lal

Ind

ic a

to r

loc

kwis

e

Tolerance

All

set t

ing

sh

ave

a t

o le

ran

ce

o

0

.05

m

m.

Fo

re

xa

mp

le

a

8

p

in io

n

cou

ld

rea

d

any

wh

ere

b

etw

ee

n

13

an

d

3

and

be

w

ithin

sp

ec

if ica

tio

n.

P

in

ion

S

h

im

s

T

h ic

kn

ess

0.

10

mm

8

72

4

569

0

. 15

8

72

4

577

0.3

0

87

24

585

0.5

0

87

24

593

9

87

26

25

9

87

26

26

7

8

72

62

75

87

26

283

7/23/2019 Saab 900 5 Speed

35/63

900 5 Speed

Teardown Pinion Depth Checks

Pinion depth

ls

easily adjusted

y

changing the shims

sandwiched between the pinion housing and

maincase. There is a one to one

re

lationship between

pinion depth and shim thickness no formulas or

calculalions re needed.

4

7/23/2019 Saab 900 5 Speed

36/63

9

5

S

pe

e

d

Pa

rt

sI

ns

p

ec

tio

n

Di

ffe

re

nt

ia l

Di

ffe

re

nti

alS

p

id e

rG

e

ar

Sh

aft

s

In

spe

ct t

he

diffe

ren

tia

l sp

ide

r ge

ar

sha

ft fo

r w

ea

r

und

er

t

he s

pid

er g

ea

rs.

T

his

ls

pa

rticu

lar

ly Im

po

rtan

t if

th

ere

I

s

evid

en

ce

o f

lub

ric

ation

p

rob

lem

s

On

ea

rlier

m

ode

ls

wh

ere

th

e

sh

a

f

t w

as r

eta

ine

d b

y s

nap

ring

s th

e sha

ft

sh

oul

d n

ot

rota

te

eas

ily

In

the

diff

ere

ntia

l h

ous

ing

. If

st

ill u

sab

le tu

m

the

sh

aft

90

t

opro

vid

e a

fres

h s

ea

t for

th

e I

nne

r d

rive

r p

lung

ers

.

I

nn

er

Dr

ive

rs

W

as

h a

nd

Ins

pec

t th

e In

ner

dri

ver

s w

ear

wi

ll ta

ke p

lac

e

where

the

ax

le

trunnion

bear

ing

contac ts the d

ri

ver

D

urin

g t

h

e reb

uild

yo

u s

ho

uld

sw

ap

the

dr

iver

s fr

om

s

ide

to

sid

e T

his

wil

l giv

e th

e

ax le

fres

h c

on

tac

t po

int

s

If

th

ere

Is su

bst

ant

ial w

ea

r t

he

ow

n

r

w

ill

com

pla

in

of a

h

ea

vy v

ibr

atio

n o

n a

cce

ler

atio

n a

s th

e a

xle

dro

ps

Int

o

a

ndc l

lmb

s o

ut o

f

the w

ea

r po

ck

et

s

5

7/23/2019 Saab 900 5 Speed

37/63

900 5 Speed

Reassembly Differential Bearing Preload

Note: The following procedure need only be

followed In its entirety

If ma

jor components

have been replaced or he original shim pack

lost. If you have the original shim pack and

there have been no major pa

rt

s changed

bypass the first two steps and

go

directly to

checking preload with a torque wrench.

1 Replace Inner driver seals, pack between the

seal li

ps

with soft grease Essa Nebula

EP2

or

equivalent). Lube the differential bearings wi

th

engine oil -

do not

use gear additives or snake

oil. Install the d ifferential and L.H. w ith speedo

dri

ve)

side cover without the d

ri

ver or

sh

ims,

torque the bolts to 14- 18

ft

l

bs

2. Install the R.H. side cover without the Inner driver,

shims or O ring. Tighten the bolts in th ree even

stages to 20 inch pounds. Measure the clearance

between the malncase and the side cover at three

po ints and average the readings. Add 0.2 mm to

this number and build a sh

im

pack equal

to th

is

thickness.

6

7/23/2019 Saab 900 5 Speed

38/63

9

5 S

pe

ed

R

eas

sem

bly

D

iffe

ren

tial

Bea

ring

Pr

eloa

d

3.

Veri

fy th

at th

e tot

al th i

ckne s

s Is

corr

ec t b

y

ins

tallin

g all

shim

s und

er th

e R.H

. sid

e c

over

torq

ue th

e bolt

sto 1

4n. b

s. Sp

inthe

differ

en tial

at

le

ast 1

Oevolu

11ons

to s

eat th

ebe a

rings

and t

hen

meas

ure p

re loa

d with

a to

rque w

renc

h an d

tool

87 9

0818

. N ew

be a

rings

sho u

ldsho

wa d

rag o

f

16 2

5 inc

h po

un ds

us e

d bea

ring s

7- 12

Inch

po u

nds .

Aller

the s

him p

ack a

sne e

ded

tobrin

g

th

epre

load w

ithin

this r

ange

.

O

nce th

ecor

re ct s

him p

ack h

as be

en se

lected

rem

ove

t

he dif

feren

tia l an

dtie

strap

the s

hims

tothe

R.H .

side

cove

r.

Note :

D

o ot

chan

ge th

e tota

l shim

pack

thick

ness

after t

his p

oint.

Th

ickn

ess

Par t

N um

ber

0.1

0m m

8

3 4

1

6

04

0

.15m

m

83 41

612

0.30m

m

83

41 620

0.50

mm

83

41 638

7

7/23/2019 Saab 900 5 Speed

39/63

9

5

S

p

e

e

d

T

e

a

rd

o

w

n

P

i

n

io

n

B

e

a

ri

ng

s

To

pr

ev

en

t

da

m

ag

e t

o

th

e

pi

n io

n

sh

a

ft

thr

ea

ds

d

ril

l

away the stake d llange of the pin ion

u

Lock the

p

in i

on

s

ha

ft I

n t

oo

l n

o.

8

3 9

06

4

an

d

rem

o

ve

th

e

nu

t.

P

re

ss

th

e

fo

rw

ar

d p

in

io

n

be

ar

ing

a

nd

h

ou

si

ng

o

ff t

he

sh

af

t.

Do

N

ot

at t

em

p

t t

o p

re

ss

o

ff

bo

th

b

ea

rin

g

s at

o

nc

e.

S

e

l

ec

t th

e

pr

op

er

pi

nio

n

ad

ap

to

r f

or

to o

l

no

. 8

7 9

06

36

lub

e

th

e

pi

n io

n

g

ea

r

an

d

pr

es

s

of

f t

he

re

a

r p

in

io

n

be

ar

ing

.

N

ot

e:

T

he

pi

ni

on

w i

ll r

ot

ate

a

s It

p

as

se

s

thr

ou

gh

th

e

fixture.

To

av oid bin din g and possib ly

ch

ipp

in

g

the

tr

ai

lin

g e

dg

e

s of

he

pi

ni o

n

te

eth

p

re s

s

th

e

be

ar

ing

o

ff

In

st

ag

es

e

as

e

of

f o

n

th

pr

es

s

an

d

re

po

si t

io

n t

he

p

in i

on

s

ev

er

al

tim

es

d

ur

ing

t

he

re

m

ov

al

pr

oc

es

s.

8

7/23/2019 Saab 900 5 Speed

40/63

9

0

0

5

S

p

ee

d

Pa

rt

sI

ns

pe

c

tio

n

- P

in

io

n

Be

a

rin

gs

H

o

us

in

gs

Pi

nio

n

e

ar

in g

s

l l le

he

art

of

the

tra

ns

mis

sio

n is

th

e p

in i

on

bea

rin

g.

Un

like

ge

ars

a

ndsy

nc

hro

sit

Isfa

lse

ec

ono

m

yto

reu

se

p in

ion

be

ari

ngs

o ran

yo

the

rbe

ari

ng

with

m

ore

tha

na

fe

wt

hou

san

d m

il e

so

fse

Nlc

e).

If y

ou

hav

eg

one

th i

sfa

r

p

ut

In

new

b

ear

ing

s,

the

la t

est

pi

nio n

b

ear

ing

s fo

r

80

- 8

8 tr

an

smi

ssi

ons

ar

e

of a

n

Imp

rov

ed

p

rofl

le d

d

esi

gn ,

S

aab

P

/N

87

24

8

90 .

Do

n't

ju

st p

ul

l th

e

univ

ers

al

num

be

r o

ff

the

old

b

ear

ings

a

nd

go

to

a

jo

bb

er, It

w

ill t

it b

ut It

wo

n't

e

rig

ht.

P

in

ion

ea

rin

g

Ho

us

ing

s

Old

er

5

spe

ed

s u

se

d a

d

ie

cas

t p in

i

on

ho

usin

g

c

har

acter

iz

ed

b

y Its

sm

oo

th

sur

fac

e fi

nish

re

qu

irin

g

r

ela

tive

ly li

ttle

ma

ch

ine

wor

k . l l

is

sty

le w

ou

ld f

all u

nd

er

sev

ere

lo

ad

cau

sin

ge

xte

nsiv

e t

ran

sm

issi

on

dam

ag

e,

th

e c

om

pla

int

w o

u ld

usu

all

y e

ha

rd

shi

fting

an

db

ein

g

loc

ked

In

o

r o

u t

of g

ear

.

Du

ring

19

82

pr

odu

ct i

on

up

gra

ded

ve

rsi

ons

we

re

Intr

odu

ce

d.

l l le

firs

t, a

sh

ort

term

s

olut

ion

, w

as

san

dc

ast

an

dc

har

act

eriz

ed

by

a

rou

gh

fin

ish

an

d

pin

kish

ti

nt

wh

en

new

.

l l le

fin

al

so

luti

on w

as

a d

li ll

c

ast

de

sig

n, S

aa

bP

/N

87 2

0 7

32.

9

7/23/2019 Saab 900 5 Speed

41/63

9

00 5

Sp

eed

P

artsI

nspec

tion

- Pin

ion B

earing

s H

ousi

ngs

Any of th

e origin

al die

cast ho

usings

shou ld

be

scrapped

even

If

they

havenot failed

An

actua

l failure

Is e

asy tosp

ot the

flange ov

er the p

inionde

pth shim

s

separa

tes

from

the

res

t

o

f the ho

using

If th ish

as

happe

ned c

arefully

Inspect

the maln

ca

sefo

r crackin

g

In the

bore

where

the

pinionh

ousing s

its You ca

n also

expec

t to find

damag

e w

here the fo

rward end

of the

pinion s

haft and

th

eInput shaft

com e t

ogether

4

7/23/2019 Saab 900 5 Speed

42/63

900

5

Sp

ee

d

R

eas

sem

bly

i

nion

Be

arin

gs

Press a

new

rear p in io n bearing on

th

pinionsh aft

usin

g too

l n o. 8

7 9 0

636a

nd r in

g 87 8

0 9 2

5 - 88

)

or

8

7

9

9

72

89-

).

N

ote:

You

r to o

l

r

th

e 89

andla

te rg

earoo

xe sm

ay

cont

act th

e st

ep

on th

e pin i

on sh

aft be

fore th

e

bear

ing Is

fully

seat

ed . T

he pi

ston

fro m a

n

o

ld slave

cyl in

der

m

a

kes

a g

ood pre

ss too

l f

th

is oc

curs .

Ins ta

ll a

new

cru

sh ab

le

l ~ e v e l oose

ly ass

em b

le the

p inio

n ho

using

, p in

ion

shaft

and

fo rw

ard p

ini on

be aring. Lubricate th e bearings wi thengin e o l l.

P

artiall

y co l

lapse

m e

c

ru

sh

able

sleev

e

by pre ss

ing

agai

nst th

e nne

r ra ce

of

th

e forw

ar dp

inion

beari

n

g

and

t

he pin

io nh

ead.

top

a

s soo

n as

youfe

el a n

y pr el

oad.

C

leana

nd lo

ctite

a n

ew

nut tighte

n

it

un

til

you

reac

h a

r

oUlng

torqu

e

of

1

8-27

Inch

poun

ds to

rquew

renc

h)

or

a pu ll

of

4.

7 - 7.

0 KG

sp rin

g sc

ale).

f you

g

o

to

o

r

strip

thea

ss em

bly , f

lt a

ne

w

cru

shab

le

sle

evea

nd s ta

rt

a

gain.

Note

:

T

urn

th

e p ini

on sh

aft

t least

1O ev

olu tio

ns to

se

at the

b ear

ingsb

efo re

taki

ng the

pre l

oad

r

eadin

g .

Sta

ke the

shou

ld er

of

he n

ut wh

en th

e pro p

er p re

lo ad

Is

atta

ine d,

use

a ro

unded

drif

t to a

vo

id spllt t

ln g th

e

l

ockin

g su rf

ace .

41

7/23/2019 Saab 900 5 Speed

43/63

900 5 Speed

Reassembly Stack Height

The internal shift linkage

in

the 900 5- speed is not

adjustable its location is fixed

by

the position

of

the

detent ball in the main case. n order to insure proper

alignment between the shift forks and synchro sleeves

the gear stack itself Is adjusted. This is done by

selectively fitting shims between reverse gear and the

pinion nut. Failure to properly set this tolerance will

result n incomplete synchronizer engagement and a

tendency

to

pop out of gear.

Note: This operation must

be

done following the

final pinion depth adjustment - pinion depth

affects stack height.

The sealing surface of the maincase must

be

clean in

order to get an accurate measurement. Adjust the shim

pack until there is the smallest possible clearance

between the tip of ool no.87 90 552 and the shim p ck

without lifting the tool away from the sealing surface of

the main case. If using a universal depth gauge the

clearance Is 195.0 - 195.1 mm. Shims are available In

thickness o f 0.30 0.40 and 0.50 mm.

.

.

42

7/23/2019 Saab 900 5 Speed

44/63

9

00

5

S

p

ee

d

Dis

as

se

mb

ly

Ins

pe

cti

on

Ge

ars

Gear

ooth

eterioration

Al

way

s ca

refu

lly c

hec

k g

ear

tee t

h ne

ar

the r

oot

for

s

igns

o f p

ittin

go

r spa

llin

g an

dot

her

dam

age

suc

has

tha t

cau

sed

y f

ore i

gn o

bje

cts o

rlack

o

rlub

rica

tion .

T

hr

ust

Su

rfa c

es

A

ll g

ear s

exc

ept

reve

rse

ride

on

bea

ring s

o r

bush

ing

s

and

n

th e

ca

se o

r th

e fo

rwa

rd g

ear

s h

av e

thru

st

sur f

ace s

to

cont

rol e

nd f

lo at

. Che

ck

the

l

.D . o

fthe

gea

r

fo r

s ig n

sof

w ea

ror

lack

o f l

ubric

atio

nan

din

spe

ct bo

th

en

d ra

ce s

for

s ig n

so r

dam

ag

e

to the

thru

st su

rfac

es.

Th

is I

s p

artlc

ula r

ty c

ritica

l o

n 4

th g

ear

whe

re

the

stepped b ushing w il l collapseIf the24mmpin ion nut ls

ove r

torq

ued

.

4

7/23/2019 Saab 900 5 Speed

45/63

900 5 Speed

Disassembly Inspection Synchromesh Sleeves

When should a part be replaced? The ability to make

this decision marks the difference between a

technician nd a parts changer. Here are some

guidelines:

Synchromesh Sleeve Friction Surface

At higher mile ge the tapered seat for the synchro ring

develops a wear pattern. If rough or w vy the sleeve

should

be

replaced. The finish

on

the surface is critical

do

not bead blast or otherwise attempt

to

recondition

tlie sleeve.

Synchromesh Engagement Teeth

These are

the

gears that grind when you miss a shift.

A certain amount of wear at thispoint is inevitable, it is a

waste of money to replace every gear

or

sleeve

Where

someone h s kissed the tip of the teeth.

. -

.

.

N W

US BLE

.

: :

f - ... .

SCR P

7/23/2019 Saab 900 5 Speed

46/63

900

5 Sp

eed

Di

sasse

mbly

Insp

ection

Sy

nchro

Ring

s

Many

technicians automatically insta

ll new synchro

rings

during

an ovemau

lrega

rdless o

f wheth

er or not

the or

iginals

show an

y signifi

cant wear

.

It

Is possib

le to

accurate ly

check

the

cond

itionof the

rings

a

s foll

ow s:

Ins

pect the ring

visu

allyfor

s

ignsof dama

ge to

the

spli

nes che

ck the fr

iction surfa

ce

for damag

e

or

co

ntamina

tionfro

m foreign

materia

l.

f th

e ring

passes

this test d

rop

It Into a

good

synchro

s

leeve. Pus

h down

gently to

seat the ring

and

measure

the

clearance

as shown

at

three

poin

ts. Bron

ze rings

must

have at le

st 1.5

mm

co

ated rin

gs at le

st 1.0

m

m clea

rance.

N

ote:

t sgood

practi

ce to che

ckall s

ynctvo ring

s

n w

and

use

d. before

Installi

ng them

In

the

transm

ission.

5

7/23/2019 Saab 900 5 Speed

47/63

900 5 Speed

Parts Identification Gears

There are three principle factors to

be

checked when

replacing gears during an overhaul or repair, they are:

Does

the

tooth count, diameter, etc. match?

Has the bearing surface changed?

Are the synchro sleeve engagement teeth the

same?

ooth

Count

There currently spring of 90) three main families of

gears that you will encounter during repair work; -1980,

1981-88, 1989- . Many

of

these gears are similar

enough

to

one another so that is possible to put

together a box with the wrong parts. Always Check

tooth count, outer diameter, root diameter and spacing.

Important differences In the first two groups may be

found on S.I. 05/82-567 section 4, page 71

of

bound

S.

I

Supplement o.3).

.

46

7/23/2019 Saab 900 5 Speed

48/63

90

0

5 S

pe

ed

Pa

rts

Iden

tific

atio

n

G e

ar

s B e

a rin

gs

S

ynch

ro Te

th

In No

ve m

ber of

1982

he tip

angl

eof h

esy n

chro s

leeve

eng

agem

ent t

eeth o

n 2nd

and

3rd g

ears w

as ch

ange

d

to I

mpro

ve cold

sh

if ting

chara

cteris

tics.

The t

eeth o

n

1he later

gears

are a

symm

etric

al. Th

eearl

ie r sty

legea

rs

are n

o long

er a

vaila

ble.

Be

aring

D

sign

he

s

uppo

rt bea

rings

t bo

th en

ds o

f the c

luste

r gear

w

ere u

pgra

ded i

n198

2pro

ductio

n. In

both

cases

the

bore

In

th

egea

rfor t

he b e

aring

wa

s In crea

sed a

nd th

e

bea

ri

ng altered accordingly. The o lder gears ha ve

been

sup

ersed

ed

by th

e ne

w er

style

and

the

ap

pro pr

iate b

earin

g. Ag

ain th

ese c

hang

es ar

e not

ed

on

S.I . 0

5/82-5

67.

In 198

9 pro

duct i

on bo

th be

aring

s

wer

efurth

er up

gra d

ed by

Incre

asing

the r

o ller c

ount

at

th e

from

to

5

and ln

the

r

ear by

insta

ll ing

a

com

bina

tion i

nner r

ace a

nd th

rust w

ashe

rbetw

een t

he

l

aysha

ft an

d the

cluste

r gea

r.

7

Sy

etr

ical

A

sym

m

t

ri

cal

.

:

:

7/23/2019 Saab 900 5 Speed

49/63

900 5 Speed

Parts Inspection Gulde Rings

Guide Rings

Inspect all guide rings, particularly those on 3rd, 4th

and 5th gears for wear or distortion. If deformed n any

way replace it. The guide rings for 3rd and 4th gears

are

locked n position y wire lock rings. There have been

two styles

n

use, circular and pear shaped. Pay

attention to the fiche and

do

not mix styles, I.e. don t

reuse an early circular ring with a new guide ring

designed for a pear shaped lock.

8

7/23/2019 Saab 900 5 Speed

50/63

9

5

S

p

e

ed

P

a

rts

In

sp

e

ct

io

n

S

yn

c

hr

o

S

pr

in

g

s

T

he

re

ar

ef

our

di

ffe

ren

ts

yn

ch

ro

spr

ing

s

In u

se

o

nt

he

9

00

5

sp

ee

d,

on

ly

3rd

a

nd

4th

g

ea

rs

sha

re

th

es

am

e

s

pri

ng

.A

lw a

ys

ch

ec

k t

he

sp

rin

gs

fo

rco

lo

rc

od i

ng

an

d

o

the

r c

ha

rac

ter

ist

ics

be

for

eI

ns

ta ll

ing

th

efn

.A

sy

ou

ca

n

s

ee

on

th

e

ch

art

th

ere

Is

a

su

bs

tan

tia

l d

if f

ere

nc

e

In

sp

rin

g

ten

s i

on

an

d

In

sta

llin

g

the

w

ro

ng

sp

rin

g

wi

ll

cr

ea

te s

h i

ftp

rob

lem

s

,(h

ar

de

ng

ag

em

en

t, g

rin

din

g I

nto

ge

ar)

.

Gear

Co

l

or

Code

1

BL

UE

G

RE

EN

3

4

W

HI

TE

5

C

LE

AR

I

ns

pe

ct t

he

sp

rin

gs

fo

rs

ign

so

d

am

a

ge

or

dis

to

rtio

n ,

(1

st

ge

ar

s

prin

g

Is

sh

or

ter

th

an

th

e

oth

er

s a

nd

I

s

m

an

uf

act

ure

d w

it

ha

s

ort

an

gl

eor

k

in

k

In

t

he

mi

dd

le

o

fth

e

co

ll).

R

ep

la c

ea

s

pri

ng

if

Its

st

iffn

es

sd

oe

sn

t

se

em

rig

ht

wh

en

c

om

pa

red

to

a

kn

ow

ng

oo

d s

pr

ing

or

In re

lat

ion

to

th

eo

the

r s

pr

ing

s.

N

o t

e :

D

u rin

gr

eas

se

mb

ly

the

e

nd

so

h

es

p r

ing

s o

r

gea

rs

1-

4 m

u

st b

e

vis

ib l

et

hro

ug

ht

wo

o

the

m

is s

ing

spl

ine

s o

th

e

syn

ch

ro

rin

g

11

s

pl i

ne

sa

pa

rt)

. T

he

sp

rin

g e

nd

sf

or

5th

g

ea

r

m

us

t

b

e 5s

pli

nes

a

pa

rt.

9

Spr

ing

Te nsi

on

PartNumber

1

0

N

87

11

10

3

30

N

87

1

51

20

2

4N

8

70

04

29

1

6N

87

15

00

5

7/23/2019 Saab 900 5 Speed

51/63

900 5 Speed

Parts Inspection - Synchro Rings Hubs

At first glance there

ap

pear to

be

only

tw

o t

ypes

of

synchro rings in

use on

the 900 5- speed. Pla in

bro

nze

wit 1a sharply ri

bbed

contact face for 1st and 4th gears

and

bronze witha gray coated contact face for 2nd and

3rd gears.

Plain

1

4

Closer inspect ion reveals that there are two versions of

each type. During 1982 production the taper angle of

the contact face was changed

and

the synchromesh

sleeve was

mod

ifi

ed

to match.

It

is critical that these pa

s on ly

be

used in sets as

shown

below

Early

87

41 1 No Longer Available)

Ignore Manufacturers Code}

i

5

Coated

2 3

Late

87

2

419

l D. for Late Cone Angle

7/23/2019 Saab 900 5 Speed

52/63

9

5S

pe

ed

Par

tsIn

te r

cha

nge

abil

ity

Ge

ars

S

yn

chro

Ri

ngs

Th

e ea r

ly sty

le sy

nctlfo

ring

s

re

still

av ail

able

for

reb

uildin

g 4 spe

ed

and

early

5

s

peed

tra

nsm

ission

s,

th e

synch

ro s

leeve

s n

ot f

th s

ynchr

o sle

eve

Is

da

mag e

d itm

us t

be re

place

d as

a pa

ckage

by

t

he

new

er st

yle sl

eevea

ndb

othn

ew er

sync

tlro rin

gs.

Th

e n

ew er

gea

rs m

ay

be

Instal

led In

o

lder

tr

ansm

ssion

sIn two

dif

feren

tco

nfigur

ations

Ne

w ge r

with

ea r

ly sty

le syn

chro

mesh

sleev

e

and

sync

hro ri

ngs

shiftq

uality

wi ll

be no

be tte

r

tha

n wit

h or ig

inalp

arts).

New gear, la te synchromesh sleeve and

both

sy

nchr

o rin g

s pro

vides

up gr

aded

shiftq

uality

).

5

7/23/2019 Saab 900 5 Speed

53/63

900 5 Speed

Parts Inspection - Shift Forks

Sh

ift forks must

be

checked for wear

on

the faces that

come ln contact with the synchromesh sleeve

as

follows:

1st, 2nd and 5th GEAR FORKS

Wear must not exceed 0 1 mm on either slde.

rd

and 4th GEAR FORKS

The silver plating must not be worn through, some

surface scratching Is allowable.

I

Maximum

0 1

mm

52

7/23/2019 Saab 900 5 Speed

54/63

9

5 S

pe

ed

Re

ass

em

bly

In

put

Sh

aft B

ea

ring

Pre

lo a

d

The input sh aft Is carried

by

a pa ir of tapered ro lle r

beari

ngs

m

uch lik e

th p in

ion

sh

t

.U

nlike

the

pinion

beari n

gsth

ere I

s nop

re loa

d th

e bea

rings

are s

e t up

u

s in g

shim s

an d

space

rs so

that

there

is z er

o dra

g o n

t

he b

e ri

ngs. Pre

lo adl

ng the

se b

eari

ngs w o

u ld p l

ace

un acc

epta

b le lo

ad s

on th e

syn

chro r

in

gs

exc e

ss ive

c

le

a

ra

nc

e

w

ould

c au s

e rap

id b

earingf

ailure

.

To se

lec tth

e p ro

pers

him p

ack p

rocee

d as

fo llo

ws :

1.

W as

h the

bea

rings

to re

m ove

th e

oi l fi l

m

nd

as

sem b

le the

In pu

t sh a

ft ass

em b

ly w it

h a

few

extr

a sh i

m s to

Insu

re tha

t you

wil lh

ave fr

eep la

y

b e

tw

eentheb earin gs and ra ce s .

2.

Su

p p or

t t he

synch

ro hu

b with

to o l

no . 8

7 90

867

an

d sim

ulate

low

er s

p

r

ock

e t nu

t tor

qu e

by

p re

ss ing

a gai

nst the

upp

er bea

ringu

sing

driftn

o.

8 4 0

75 w i

th a fo

rce

of 3 ton

s.

3

. S

eat t

he be

aring

s

by

ro tat

ing th

e ho

using

1O

tim e

s a ga

in st

b

o

thth

e upp

er an

d l ow

er b e

arings

.

4.

Bo

lt th e

d ia l

Ind ica

tor an

d b ac

k lash

fix tu

re tot

h e

b e

aring

hous

ing.

Zero t

h e in

dica to

r aga

instt

he

b as

e p la

te of

t

he p re

ss w

h ile pr

essin

g d ow

nwa

rd

o n

the h

ousin

g . Lif

t

the hous

in g.

Su

btrac

th

e

I

n

d ic

ate d

cl ea

rance

from

th e

sh im

p a c

k

nd

re te

st.

5

7/23/2019 Saab 900 5 Speed

55/63

9 5 Speed

Reassembly - Input Shaft Bearing Preload

Reassembly - Input Shaft Bearing Preload

5. You should come as close to zero clearance as

possible without putting

any

drag on the

bearings. You

may

change spacers as well

as

shlms to get the right combination.

Note: Shims always go next to the rear bearing.

Shim

Thickness Part Number

0.20 mm 8712 994

0.25mm 8713 448

0.30 mm 87 13 455

Spacer Thickness - 88) Part Number

7.28mm 8723

272

7.29mm 87 23 280

7.30mm 87 23 298

7 31

mm 87 23 306

Spacer Thickness

89-)

Part Number

5.28mm 87 26 184

5.29 mm 87 26 192

5.30mm 87 26 200

5.31 mm 87 26 218

54

.

7/23/2019 Saab 900 5 Speed

56/63

9

5Sp

eed

Part

s Ide

nti fica

tion

Inpu

t Sha

fts

Bear

ingHo

u sin

g s

Th ere are severl variati onsof Inpu t shaft and beari ng

hous

ings In u

se The

ir app li c

at ionva

ri es w ith

m ode l

yearan

d engin

e fam i

ly Various

combin a

tions

of

these

partsa

re possi

ble The

m ajor a

reaso f

change

are:

T

he d ista

nce bet

weenb e

aringra

ces on t

he Input

s

haft bea

ri

ng

sup

port

S lig

ht varia t

ions in t h

e overa

ll length

of th epo

rtion

of t

he

shaftwhere the bearings ride

The

addition

of

a fo r

ward su p

port bea

ring o

n some

1 fN Tu

rbos

T

he o

n

ly

se rio u

s m ista

ke yo u

cou ld

m ake

by

m

ism atch

ing par

ts woul

d beto

create

a cond

it ion

whe

re thefo

rwardn

ut would

bottom

out on

th

e thread

s

befo r

e proper

bearin g

preload

Is obta i

ned Th

is w ou ld

be caus

ed

by

c

omb in in

g a narr

ow hous

ing w ith

a long

s

haft

7/23/2019 Saab 900 5 Speed

57/63

900 5 Speed

Reassembly Ring and Pinion Backlash

Before assembling the transmission you selected the

proper shim pack for carrier bearing preload.

In

this

operation you will redistribute the shims to obtain the

correct backlash.

Begin with two thirds of the shims mounted on the right

hand side of the transmission. This will prevent you

from crowding the ring gear into the pinion when you

tighten down the side cover bolts 14-18

t

lbs).

Measu.re the backlash and compare to the

specif

ications

you took during

disassembly Calculate

the difference between the two readings and move

shims of a corresponding thickness to the left hand

side bea

ri

ng seat. Recheck backlash atfour points and

make f inal adjustments

if

needed.

If the backlash reading varies by more than 0.05 mm

remove the ring gear and position the dial Indicator

agalnstthe faceof he differential housing. checking or

runout much as you would on a brake rotor. The

maximum allowable variation is 0.05 mm.

56

Specification

17

05

mm

I

7/23/2019 Saab 900 5 Speed

58/63

9

5

Spe

ed

P

arts

Ins

pec

tion

P

rim

ary

C h

ains

Although

they rarely fall outright

the

primary chains

o

wea

r

a

nd

stre

tch d

uring

their

life. A

simp

leme

thod

to

determ

ine tf

the c

hain

s

h

ave

reac

hed t

heir w

ear li

mit is

to c

heck

for c l

earan

cebe

twee

n

th

e

prim

aryho

using

an

d c

hain

s at the

rub

bing b

lock

. Ifyo

u have

less

th

an

1 m

mon

both

sides

th

e

c

hai

ns shou

ldbe

repla

ced.

Wh

en tea

ring

down

the

t

ransm

issio

n labe

l the

chain

s

as

t

o loca

tion

- o

uter mid

dle and

lm

er. Th

ey wear

at

sligh

tly diff

e

7/23/2019 Saab 900 5 Speed

59/63

900 5 Speed

Shift Linkage Adjustment

There arethree principle styles

of

selectormechanisms

in use each with Its own adjustment procedure.

198 Mid 1982

Adjustment Is carri

ed

out

by

locking the shift lever

n

reverse with the ignition key and checking for freeplay

when rocking the shift lever fore and aft. There should

be 3 4

mm

movement. Adjustment is made

by

loosening

the

three

tr obed

selector housing

mounting nuts and moving the housing forwar

ds

or

backWards until the correct clearance is obtained.

Mid 1982 Mid 1986

The

change

r

between the two styles is easily

spotted the late r version has

an

alignment hole

th

rough thefront of the shifter housing and selector rod.

Adj

ust

as

follows

1. Select reverse gear.

2. Loosen the clamp on the selector rod above the

steering rack.

3. Lock the selector rod in positi

on by

dropping a

6mm pin through the ho le at the front of the shifter

housing.

4. Torque the

bo

lt on the clamp to 22- 26 ft l

bs

.

l

8

7/23/2019 Saab 900 5 Speed

60/63

9

5

Sp

ee

d

Sh

ift

Li

nk

age

A

d ju

st

me

nt

Mid

19

86

On

wa

rd

At

first

g lan

ce t

he

m

ech

anis

m a

ppe

ars

to b e

the

sam

e

b

ut th

ere

are

th re

e Im

po rt

ant

diffe

re nc

es:

1

The

6

m m

p in

ho

le s

line

u

pIn

rd g

ear

-

n

ot

r

eve

rse.

2

n

1es

prin

g lo

ade

d se

lect

or ce

nte r

ing

m ec

han

ism

has

d is

appe

are

d fr

om

the

front

ofth e

se le

c to r

hou

sing

. Th

e f un

ct io

n

s

In te

rnal

to

th

e g

earb

ox.

3

h

egea

rbox

rea

r

co

ve r

h

as

gu

id e

sl o t

an d

the

se

le cto

r

rod a

new

h

o le

to a

ccep

t al

ock

in gt

oo lt

o

ins

ure

th e

l inka

ge

Is co

rr ec

tlya

lig n

ed.

Ad

just

as fol l

ows

:

1 .

Sele

ct th

ir d

gear

ins

ta ll

th e lo ck

in g

too l

on

the

rear

co

ver

o t

he ge a

rb o

x.

2.

Lo

ose

n th

e p in

ch b

o lt

on th

e se

le c

tor r

od cl

amp

3

.

Loc

k th e

sh

ift le

ve r

In to

th ird

ge

ar w

ith t

he 6

mm

p in .

4 .

T

ighte

n th

e p

in cn

b o l

t on

the

c la m

p

t

o

22

- 26

f

t

lb s.

59

7/23/2019 Saab 900 5 Speed

61/63

9

00

5 S

pe

ed

S

hift

L in

kag

e

djus

tm

ent

198

0 M

id 1

986

Cen

terin

g M

ech

anis

m

All

5 s

peed

trans

m iss

io ns

have

a m

ech a

nism

to

autom

atica

lly ce

nter

th e sh

ift le

ver in

the

3 - 4th

gear

slo

t.

U

p u

nt l mi

d 19

86 thi

swas

acco

m plis

hed

by a p

air

o f sp

ring l

o d

edro lle

rs m

ounte

d on

the f

ront o

fthe

selec

tor ho

using

.

A

djus

t as fo

llows

1.

Rem

ove

the c

onso

le , dr

ivers

seat

and

left s

il l

p la

te . Fo

ld

b

ack

t

he carpe

tto un

cove

rthe t

unnel

.

2 . Engage 3rd gear.

3

. L

oosen

the

o re

ta in in

gscre

ws lo

ci

7/23/2019 Saab 900 5 Speed

62/63

9

5

S

p

e

e

d

S

la

v

e

C

y

li

n

de

r

-

C

l

u

tc

h

W

e

a

r

T

he

s

la

ve

c

yl

in d

er

fo

r

th e

Saab 5 speedIs aunique

co

-a

x i

a l

de

si

gn

w

ith

a

h

oll

ow

pis

to

n

su

rro

un

di

ng

th

e

clu

tc

h

sh

af

t. t

Is

s

elf

ad

ju

st i

ng

, m

u

ch

li k

e

a

d is

k

bra

k

e

ca

llp

er

.

In

p

ri n

ci

p le

a

ll y

e

ars

fu

n

ct i

on

al

on

g

the

s

am

e

lin

es

b

ut

t

he

re

ar

e

so

m

e

sig

n

ific

an

t

ch

an

ge

s

wh

ic

h

af f

ec

t t

he

fo l

l

o

w

in

g

op

er

at

io n

s.

C

h

ec

k

in

g

C

lu

tc

h

D

is

k

W

e

ar

F

ro

m

th

e

se

rv i

ce

st

an

dp

o

in t

th

e s

in

gl

e m

o

st

Im

po

rta

n

t

pa

rto

f

th e

s

la

ve

cy

lin

de

ris

the

s

lid

in

g d

us

t s

hi

eld

.

he

shie ld

has

tw o fun ct ions;oneistoprotect theex po

se

d

p

or

tio

ns

of

t

he

cy

lin

de

r,

th

e

oth

e

r Is

to

a

ct

a

s a

tr

av

el

s

to

pt

o

pr

ev

en

t t

he

p

is t

on

fro

m

re

tr

ac

tin

g t

oo

fa

r

wh

en

t

he

c

lu t

ch

Is

re

le

as

ed

.

T

h

e

po

s i

ti o

n o

f

t

he

s

le

ev

e

pr

ov

id

es

a

n

a

cc

ura

te

In

dic

at

io n

of

c

lu