Transaxle Reassembly

1. Blow out ventilation channels with compressed air. Install pinion bearing housing Locating Studs (87 91 014) into case. Install pinion bearing shims. Lubricate bearing housing sealing rings.
2. Position complete pinion bearing housing assembly on locating studs. Place case in press and press in housing as far as it will go. Remove locating studs and install retaining bolts with locking compound. Check pinion clearance.
   NOTE: Pinion depth must be measured using Saab Measuring Instrument (83 90 155). See Fig 2 .
3. To calibrate indicator, place calibration stops of measuring tool against gauge block. Distance between stops and center line of tool is 2.362" (60.00 mm), which is equal to distance from end face of pinion shaft to center line of ring gear. Ensure dial indicator pointer is zeroed when measuring tip touches gauge block.
4. Place measuring tool in transaxle case with measuring tip applied to flat end of pinion gear. When pinion gear is correctly positioned, dial indicator should show number of hundredths of a millimeter (+ or -) stamped into pinion, with an allowed tolerance of .002" (.05 mm). For example, if pinion is stamped +3 indicator should read +3 plus or minus .05 mm. See Fig 1 .
5. If measured pinion depth reading is not within specification (stamped on pinion), pinion shaft must be adjusted. To adjust, remove pinion shaft bearing housing. Add or remove shims between housing and transaxle case. If reading is higher than specification, reduce shim combination.
6. Reduce or increase shim combination according to difference between measured value and specified value. Pinion depth adjusting shims are available in thicknesses of .004" (.10 mm), .006" (.15 mm), .012" (.30 mm) and .020" (.50 mm).
7. Place transaxle housing in press and support pinion with a Sleeve (78 41 067). Lubricate seals of output shaft. Position output shaft on pinion and carefully press on shaft. Ensure shaft and pinion splines are properly aligned. Ensure sealing rings on output shaft are located correctly in their grooves as they enter seal housing. Turn gear housing back and forth while pressing together.
8. If parking pawl was removed during disassembly, reverse removal procedure to install. Lubricate front and rear servo piston seals. Install pistons into servo cylinders in transaxle case.
9. Install rear brake band. Measure assembly depth in case with a large depth gauge. See Fig 2 . Total depth should be 7.561-7.578" (192.04-192.48 mm) including shims. Install thrust bearing, race and shims in planetary gear assembly. Install planetary gear and center support. Install front brake band.
10. Lubricate and install a thrust needle bearing on each side of sun gear on sun gear shaft. Carefully insert sun gear shaft into rear clutch assembly. Use care not to damage oil seal ring on shaft. Lubricate rear clutch sealing rings and install complete unit so teeth mesh with planetary gear.
11. Install, in order, large bearing race, needle bearing and small washer in front clutch. Install front clutch assembly. Lubricate input shaft sealing rings and install shaft. Note position of lugs when properly installed. See Fig 3 .
12. Place pin in rear servo piston. Place long band apply strut against rear band. Place rear band apply lever in position and insert shaft from side until it protrudes approximately .04" (1.0 mm). Turn ring gear so lower screw of governor is in line with hook of parking pawl.
13. Hold spring in place while sliding shaft into position so it is engaged on shaft. Place short strut against front band. Place lever in position and press in lever shaft from side.
    NOTE: When installing rear servo piston pivot shaft and spring, one end of spring must be in contact with lever at all times to prevent scratching servo cylinder.
14. Lubricate transaxle housing-to-torque converter housing mating surface. Install gasket to transaxle housing. Lubricate axial play thrust washer and shims and install inside front bearing (in torque converter housing). Install shims first. Ensure drain valve oil tubes are in position. Install torque converter.
15. Place gear selector rod in transaxle case. Install torque converter housing-to-transaxle case. Install converter housing-to-transaxle case attaching bolts. Check transaxle gear unit end play. Install chain sprocket on input shaft and mount a dial indicator on torque converter housing so indicator tip is touching end of input shaft.
16. Zero indicator. Pry forward on planetary gear assembly and read gear end play. End play should be .010-.030" (.25-.75 mm). If end play is not to specification, adjust by adding or removing shims between thrust washer and front bearing. See Fig 4 .
17. Remove chain sprocket and install accumulator plate. Install oil pipes No. 16 and 17. See Fig 5 . Insert pivot pin into shift lever and hook onto gear selector rod. Install accumulator plate into place with shift lever connected. Ensure that accumulator piston is installed prior to installing plate.
18. Install 2 oil pipes into 3rd-2nd drain valve and install mounting bolts. Turn transaxle over and install torque converter. Install Locating Studs (87 90 438) into tapped holes for securing oil pump. Ensure holes for pump drive correspond to drive pins of torque converter. Lubricate "O" rings on pump and install. Remove locating studs and torque mounting bolts.
19. Install transaxle support and turn transaxle upside down. Install neutral/drive accumulator with suction pipe and clamp. Install delivery pipes. Install throttle cable into torque converter housing. Place valve body into position. Ensure manual valve controls are engaged. Align valve body with 5 mounting bolts, tighten bolts No. 3 and 4 and remove bolts No. 1, 2 and 5. See Fig 6 .
20. Connect throttle cable to cam on valve body. Ensure that cable is routed correctly. Move selector rod to "P" position. Half of plunger should be visible behind parking pawl and plunger should be in contact with dowel. Move selector rod to "R" and measure clearance between pawl and top of teeth. Clearance must be less than 0.35" (.9 mm). Install oil pipes in their correct positions. See Fig 5 . Adjust front and rear bands. See Fig 7 . Torque adjusting screw lock nut to 15-20 ft. lbs. (20-27 N.m).
21. Install chain and sprockets. Place lock plate under retaining nuts and tighten nuts. Use a bar between sprockets to hold them in place while torquing bolts. Check distance between torque converter and chain. Distance must be closer than 1/2". Install oil dip stick. Install differential assembly and bearing housings.
22. To check ring gear backlash, mount dial indicator on transaxle case so indicator tip is touching ring gear teeth. See Fig 8 . Measure backlash. Check backlash at 4 different points around ring gear. Measurement must not vary by more than .002" (.05 mm) from specification. See Fig 9 .
    NOTE: Backlash with a new ring and pinion set (or used set with less than 6000 miles of service), should be within specifications which appear on ring gear. See Fig 9 . If used gear set (more than 6000 miles of service), is to be installed, backlash should be same as recorded during disassembly.
23. Calculate difference between measured backlash and backlash reading desired. Move shims of correct thickness from right bearing housing to left side housing. DO NOT add or remove any shims. Combination of shims installed has been preselected and must not be changed.