- Place a screwdriver through differential assembly to prevent pinion gears from slipping out of position. Install magnet. Install differential assembly in clutch housing. Place output shaft in seat. Tap down on output shaft with plastic mallet, then press shaft fully into housing using Puller (8791287) and Attachments (8791246 and 8791295). Install bearing bracket. Tighten bearing bracket bolts to 18-21 ft. lbs. (24-28 N.m).
- Install springs and plungers for 1st-2nd gear synchronizer in hub. Install synchronizer sleeve, with beveled side of teeth facing inward. Ensure deep slots are aligned. Position rollers in synchronizer. Install 2nd gear baulk ring and gear. Secure 2nd gear synchronizer assembly with Holder (8791162). Secure holder with wire.
- Install 1st and 2nd gears and synchronizer assembly with 2nd gear bushing on output shaft. Temporarily place a .59" (15.0 mm) spacer under 1st gear. Place 3rd gear on output shaft. Install reverse gear, idler shaft and bushing. Ensure beveled side of gear teeth are facing upward.
- Install input shaft assembly. Secure input shaft to output shaft with a piece of wire. Remove spacer from under 1st gear. Press down on gears on output shaft, rocking back and forth until settled in place. Install spacer tube and 4th gear. Remove adapter from synchronizer assembly.
- Install thrust washer on output shaft with convex side up. Install plain washer. Install selector shaft assembly. Tighten set screw to 15-18 ft. lbs. (20-24 N.m). Install reverse gear selector fork. Tighten set screw to 15-18 ft. lbs. (20-24 N.m). Position selector shaft actuator and insert selector rod, tighten set screw to 15-18 ft. lbs. (20-24 N.m). Apply Loctite (242) to set screw.
- Engage 1st gear. Check selector interlock operation by trying to shift into reverse with a wrench. If transaxle cannot be shifted into reverse, interlock is installed correctly. Ensure sliding gear for reverse is not pressed against clutch housing. Axial play should be .004-.04" (.10-1.0 mm). If there is no play, insert washer of correct thickness under fork. Ensure actuator hole for reverse idler shaft is aligned with shaft hole. Apply Loctite (510) to clutch housing-to-transmission housing mating surface.
CAUTION:
DO NOT
apply sealing compound to gearbox vent (centered plug).
- Apply multipurpose grease to spring and plunger. Install spring and plunger in driver shaft. Install transmission housing on clutch housing. Ensure spring and plunger are in position. Spring pressure should be felt when installing housing.
Courtesy of SAAB-SCANIA OF AMERICA, INC.
Courtesy of SAAB-SCANIA OF AMERICA, INC.
- Install reverse gear idler shaft bearing bolt. Install 2 clutch housing-to-transmission housing bolts. DO NOT
tighten bolts. Install dowels. Position dipstick tube and tighten housing bolts to 15-18 ft. lbs. (20-24 N.m). Press output shaft bearing until it contacts race.
CAUTION:
DO NOT
press gear on so far that bearing end play is removed.
- Press 5th gear on output shaft just enough to contact bearing. Install 5th gear, needle bearing, baulk ring and synchronizer hub on input shaft. Install synchronizer sleeve with beveled edge teeth facing downward. It should mesh with 5th gear. Install NEW lock nut.
- Position a dial indicator against output shaft. See Fig 1. Using a screwdriver to pry output shaft, check output shaft end play. Tighten lock nut until end play is .008" (.20 mm). Tighten lock nut an additional 180 degrees. Peen collar of nut to lock in place.
- Remove 5th gear and synchronizer from input shaft. Attach a dial indicator to input shaft. See Fig 2. Using an electric drill and Adapter (8791248), rotate input shaft and check end play. Install proper shim under bearing bracket to obtain .002-.004" (.05-.10 mm) end play.
- Fit 5th gear baulk ring and synchronizer cone together. Measure gap between baulk ring teeth and cone teeth with feeler gauge. Gap should be at least .031" (.8 mm). See Fig 3. If gap is less than specified, replace baulk ring. Install 5th gear, needle bearing, baulk ring and synchronizer hub on input shaft.
CAUTION:
When installing 5th gear selector fork, DO NOT
use excessive force as damage to spring may result.
Courtesy of SAAB-SCANIA OF AMERICA, INC.
- Install synchronizer sleeve and selector fork. Install springs, plungers, rollers, triangular plate and snap ring. Tighten triangular plate Torx screws to 18-21 ft. lbs. (24-28 N.m). Install roll pin into reverse selector shaft.
- Install end cover and gasket, tighten cover bolts to 15-18 ft. lbs. (20-24 N.m). Ensure transaxle shifts into all gears. Install speedometer drive pinion. Install axle shafts and bearing. Install retaining ring, "O" ring and dust cover.