Transaxle Reassembly

NOTE: Lubricate all components with ATF before reassembly. Use petroleum jelly to hold gaskets and thrust washers in place. Ensure thrust washers and bearings are installed in correct locations. See Figure .

Thoroughly clean case and blow out passages with compressed air. Install pinion bearing housing Locating Studs (8791014) into case. Install pinion bearing shims. Lubricate bearing housing sealing rings.

NOTE: Pinion depth must be measured using Saab measuring instrument (8390155). See Fig 1 .

Position complete pinion bearing housing assembly on locating studs. Place transaxle case in press. Using press Adaptors (8390148, 8390114 and 8791352), press in housing as far as it will go. Remove locating studs and install retaining bolts with locking compound. Check pinion clearance.
To calibrate indicator, place calibration stops of measuring tool against gauge block. Distance between stops and center line of tool should be 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.
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 2 .
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.
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).
Install ring gear and governor assembly in case. Place transaxle housing in press and support pinion with Sleeve (7841067). 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.
Using a large depth gauge, measure distance between outer surface of transaxle and thrust bearing including shims. Measurement should be 7.561-7.577" (192.04-192.48 mm). Install rear band. Ensure band is facing proper direction. Install thrust bearing, race and shim, on planetary gear assembly. Install planetary gear and center support. Apply sealing compound to center support bolt in oil pan.
Install front band; check direction of band. Lubricate and install a thrust needle bearing on each side of pinion 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.
Lubricate front and rear servo piston seals. Install pistons into servo cylinders in transaxle case. 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. Install front cover, noting position of lugs on cover. See Fig 3 .
Place pin in rear servo piston. Place long band apply strut against rear band. If parking pawl was removed during disassembly, reverse removal procedure to install.
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.

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.

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. Slide gear selector rod into case.
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 housing-to-transaxle case and secure with 2 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.
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 . Install remaining torque converter housing bolts and tighten to 10-15 ft. lbs. (14-21 N.m). Install Locating Studs (8790438) in oil pump bolt holes. Install oil pump.
Install oil tubes No. 1, 2, 3 and 4. See Fig 5 . Insert pivot pin into shift lever and hook onto gear selector rod. Install N-D accumulator piston and 1-2 accumulator piston and accumulator plates. Install shift lever and plate. Fit drain valve with No. 15 oil tube.
Lubricate suction tube with petroleum jelly. Install delivery tubes into case positioned 1.06" (27 mm) from side of case. Check adjustment of manual valve and kickdown valve before installing valve body into transaxle case.
To check position of manual control valve, slide valve to "N" position. Sealing surface should be located directly over bridge cast between end plate and hole through which valve is visible. To adjust, loosen 2 bolts retaining spring mounting bracket and move bracket along length of range selector valve. Spring must be centered and aligned with manual control valve. See Figure .
To check position of kickdown valve cam, insert a .039" (1.00 mm) feeler gauge between cam disc and side of kickdown valve. This should align throttle valve so there is a tiny gap between valve and housing. See Figure . To adjust, loosen cam carrier retaining bolts and move carrier along length of valve.
Install throttle cable into torque converter housing. Place valve body into position. Ensure manual valve controls and oil tubes are properly engaged. Align valve body with 5 mounting bolts, tighten bolts No. 3 and 4, and remove bolts No. 1, 2 and 5 (to be installed later). See Fig 6 .
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 .35" (.9 mm). Install remaining oil tubes in their correct positions. See Fig 5 . Install oil strainer and bolts No. 1, 2 and 5. Adjust front and rear bands. See FRONT BAND and REAR BAND under ON-VEHICLE REPAIRS\ADJUSTMENTS. Tighten adjusting screw lock nut to 15-20 ft. lbs. (20-27 N.m).
Install chain and sprockets. Place lock plate under retaining nuts and tighten nuts. Use a bar between sprockets to hold them in place while tightening bolts. Check distance between torque converter housing and chain. Distance must be a minimum of .4" (10 mm). Install oil dipstick. Install differential assembly and bearing housings.
To check ring gear backlash, mount dial indicator on transaxle case so indicator tip is touching ring gear teeth. See Fig 7 . 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 8 .
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.