LEMON Manuals: Even more car manuals for everyone
Home >> Saab >> 2005 >> 9-2X Linear, 251, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission >> Adjustment/Replacement/Inspection >> A/T Main Case >> Installation

A/T Main Case: Installation

Install the low & reverse piston without tilting.

NOTE: Be careful not to damage the lip seal.
Fig 1: Installing Low & Reverse Piston
G03874982Courtesy of SAAB-SCANIA OF AMERICA, INC.

Install return spring.

Fig 2: Installing Return Spring
G03874983Courtesy of SAAB-SCANIA OF AMERICA, INC.

Install spring retainer.

Fig 3: Installing Spring Retainer
G03874984Courtesy of SAAB-SCANIA OF AMERICA, INC.

Install the one-way clutch inner race, spring retainer and return spring.

Tighten socket head bolts evenly from the rear side of the transmission case.

Tightening torque: 

25 Nm (2.5 kgf-m, 18.1 ft-lb) 

Fig 4: Tightening Socket Head Bolts
G03874985Courtesy of SAAB-SCANIA OF AMERICA, INC.

Place the front side of transmission body up.

Install thrust needle bearing.

Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.

Set the micro gauge to retaining plate, and read its scale. Make more than three measurements at even distance and take the average value.

NOTE: The value, which is read in the gauge at this time, is zero point.

Scale and record the weight "Z" of a flat board which will be put on plates.

NOTE:
  • Use a stiff flat board which does not bend against load.
  • Use a flat board of its weight less than 83 N (8.5 kgf, 18.7 lb).

Put the flat board on retaining plate.

Fig 5: Installing Micro Gauge
G03874986Courtesy of SAAB-SCANIA OF AMERICA, INC.

Using the following formula, calculate "N" indicated on the push/pull gauge.

N = 83 N (8.5 kgf, 18.7 lb) - Z

N: Value indicated on push/pull gauge

83 N (8.5 kgf, 18.7 lb): Load applied to clutch plate

Z: Flat board weight

Press the center of retaining plate applying force of N with push/pull gauge, and then measure and record the height A. Make more than three measurements at even distance and take the average value.

NOTE: If three points, measure the height every 120°. If four points, measure the height every 90°.
Fig 6: Measuring Height
G03874987Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. Dish plate
  2. Driven plate
  3. Drive plate
  4. Retaining plate

Installation of the low & reverse brake:

Install the dish plate, driven plate and retaining plate, and then secure them with snap ring.

NOTE: Pay attention to the orientation of dish plate.
Fig 7: Installing Dish Plate
G03874988Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. Snap ring

Apply compressed air intermittently to check for operation.

Fig 8: Applying Compressed Air
G03874989Courtesy of SAAB-SCANIA OF AMERICA, INC.

Place the same thickness of shim on both sides to prevent the plate from tilting, and then measure and record the clearance B.

NOTE: Do not press the shim downward with excessive force, or else the waveform of drive plates will be broken down.
Fig 9: Measuring Clearance
G03874990Courtesy of SAAB-SCANIA OF AMERICA, INC.

Piston stroke calculation

Select the retaining plate within the specification by calculating with A and B dimensions which have been recorded before. If the calculated value exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.

T = A + B

T: Piston stroke

  1. A: Collapse amount of drive plate
  2. B: Clearance between retaining plate and snap ring

Saab 9-2X 2.5i Linear 

Initial standard: 

2.15 - 2.65 mm (0.073 - 0.093 in) 

Limit thickness: 

2.95 mm (0.104 in) 

Saab 9-2X 2.0T Aero 

Initial standard: 

2.70 - 3.20 mm (0.106 - 0.126 in) 

Limit thickness: 

3.90 mm (0.154 in) 

THICKNESS REFERENCE

Retaining plate
Part number Thickness mm (in)
32006573 3.8 (0.150)
32006566 4.1 (0.161)
32006567 4.4 (0.173)
32006568 4.7 (0.185)
32006569 5.0 (0.197)
32006570 5.3 (0.209)
32006571 5.6 (0.220)
32006572 5.9 (0.232)

Install the low & reverse brake leaf spring.

Fig 10: Installing Low & Reverse Brake Leaf Spring
G03874991Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. Leaf spring

Install the 2-4 brake piston and 2-4 brake retainer by aligning hole of 2-4 brake retainer and hole of transmission case.

Fig 11: Installing Brake Piston And Brake Retainer
G03874992Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. 2-4 brake piston
  2. 2-4 brake piston retainer

Install 2-4 brake piston return spring to transmission case.

Fig 12: Installing Brake Piston Return Spring To Transmission Case
G03874993Courtesy of SAAB-SCANIA OF AMERICA, INC.

Position snap ring in transmission. Using ST, press the snap ring into place.

ST 32005113 COMPRESSOR 

Fig 13: Pressing Snap Ring Using ST 32005113 Compressor
G03874994Courtesy of SAAB-SCANIA OF AMERICA, INC.

Install planetary gear and low clutch assembly to transmission case.

Install carefully while rotating the low clutch and planetary gear assembly slowly paying special attention not to damage the seal ring.

Fig 14: Installing Planetary Gear And Low Clutch Assembly
G03874995Courtesy of SAAB-SCANIA OF AMERICA, INC.

Selection of 2 -4 brake retaining plate (Saab 9-2X 2.0T Aero)

Install pressure plate, drive plate, driven plate, retaining plate and snap ring.

Fig 15: Installing Pressure Plate, Drive Plate, Driven Plate, Retaining Plate And Snap Ring
G03874996Courtesy of SAAB-SCANIA OF AMERICA, INC.

Install a new 2-4 brake oil seal to transmission case.

Fig 16: Installing Brake Oil Seal To Transmission Case
G03874997Courtesy of SAAB-SCANIA OF AMERICA, INC.

After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of the brake.

Fig 17: Applying Compressed Air
G03874998Courtesy of SAAB-SCANIA OF AMERICA, INC.

Check the clearance between the retaining plate and the snap ring.

NOTE: Select a retaining plate with a suitable value from the following table, so that the clearance becomes the standard value.
If it exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.

Initial standard: 

0.8 - 1.2 mm (0.031 - 0.047 in) 

Limit thickness: 

1.5 mm (0.059 in) 

Fig 18: Checking Clearance Between Retaining Plate And Snap Ring
G03874999Courtesy of SAAB-SCANIA OF AMERICA, INC.
THICKNESS REFERENCE

Retaining plate
Part No. Thickness mm (in)
32006521 5.6 (0.220)
32006522 5.8 (0.228)
32006523 6.0 (0.236)
32006524 6.2 (0.244)
32006525 6.4 (0.252)
32006526 6.6 (0.260)

Selection of 2 -4 brake retaining plate (Saab 9-2X 2.5i Linear)

Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.

Set the micro gauge to clutch, and read its scale.

NOTE: The value, which is read in the gauge at this time, is zero point.

Scale and record the weight "Z" of a flat board which will be put on plates.

NOTE:
  • Use a stiff flat board which does not bend against load.
  • Use a flat board of its weight less than 100 N (10.2 kgf, 22.5 lb).

Put the flat board on retaining plate.

Fig 19: Installing Micro Gauge
G03875000Courtesy of SAAB-SCANIA OF AMERICA, INC.

Using the following formula, calculate "N" indicated on the push/pull gauge.

N = 100 N (10.2 kgf, 22.5 lb) - Z

N: Value indicated on push/pull gauge

100 N (10.2 kgf, 22.5 lb): Load applied to clutch plate

Z: Flat board weight

Press the center of retaining plate applying force of N with push/pull gauge, and then measure and record the height A. Make more than three measurements at even distance and take the average value.

NOTE: If three points, measure the height every 120°. If four points, measure the height every 90°.
Fig 20: Measuring Height
G03875001Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. Driven plate
  2. Drive plate
  3. Retaining plate

Install the pressure plate, drive plate, driven plate, retaining plate and snap ring.

Fig 21: Installing Pressure Plate, Drive Plate, Driven Plate, Retaining Plate And Snap Ring
G03875002Courtesy of SAAB-SCANIA OF AMERICA, INC.

Install a new 2-4 brake oil seal to transmission case.

Fig 22: Installing Brake Oil Seal To Transmission Case
G03875003Courtesy of SAAB-SCANIA OF AMERICA, INC.

After all 2-4 brake component parts have been installed, blow air intermittently and confirm the operation of brake.

Fig 23: Applying Blow Air
G03875004Courtesy of SAAB-SCANIA OF AMERICA, INC.

Measure and record the clearance B between the retaining plate and snap ring.

Fig 24: Measuring Clearance
G03875005Courtesy of SAAB-SCANIA OF AMERICA, INC.

Piston stroke calculation

Select the retaining plate within the specification by calculating with A and B dimensions which have been recorded before. If the calculated value exceeds the usage limit, replace the drive plate with a new one and adjust it within the specitication.

T = A + B

T: Piston stroke

A: Collapse amount of drive plate

B: Clearance between retaining plate and snap ring

Initial standard: 

1.7 - 2.1 mm (0.067 - 0.083 in) 

Limit thickness: 

2.3 mm (0.091 in) 

THICKNESS REFERENCE

Retaining plate
Part number Thickness mm (in)
32006521 5.6 (0.220)
32006522 5.8 (0.228)
32006523 6.0 (0.236)
32006524 6.2 (0.244)
32006525 6.4 (0.252)
32006526 6.6 (0.260)

Be careful not to mistake the location of the leaf spring to be inserted.

Fig 25: Measuring Clearance
G03875006Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. Leaf spring
  2. Retaining plate

Install thrust needle bearing in the correct direction.

Fig 26: Installing Thrust Needle Bearing
G03875007Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. Snap ring
  2. Thrust needle bearing
  3. Upside
  4. Downside
  5. Outside

Install front sun gear and thrust needle bearing.

Fig 27: Installing Front Sun Gear And Thrust Needle Bearing
G03875008Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. Front sun gear
  2. Thrust needle bearing
  3. Clutch hub side
  4. Front sun gear side
  5. Outside

Install the high clutch hub.

Attach the thrust needle bearing to the hub with vaseline and install the hub by correctly engaging the splines of the front planetary carrier.

Install the thrust needle bearing in proper direction.

Fig 28: Installing Thrust Needle Bearing
G03875009Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. High clutch hub
  2. Thrust needle bearing
  3. Upside
  4. Downside
  5. Outside

Install the high clutch assembly.

Fig 29: Installing High Clutch Assembly
G03875010Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. High clutch and reverse clutch ASSY

Adjust total end play.

Install the thrust needle bearing in proper direction.

Fig 30: Installing Thrust Needle Bearing
G03875011Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. High clutch and reverse clutch assembly
  2. Thrust needle bearing
  3. Upside
  4. Downside
  5. Outside

Install the oil pump housing assembly.

Install the converter case assembly to the transmission case assembly.

Insert inhibitor switch and transmission connector into stay.

Install air breather hose.

Fig 31: Installing Air Breather Hose
G03875012Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. Transmission harness
  2. Inhibitor switch harness

Install oil cooler pipes.

Install the oil charge pipe with O-ring.

Insert the input shaft while turning lightly by hand. At this time, not to damage the bushing.

Normal protrusion A: 

50 - 55 mm (1.97 - 2.17 in) 

Fig 32: Inserting Input Shaft
G03875013Courtesy of SAAB-SCANIA OF AMERICA, INC.

Install the torque converter clutch assembly.

Install the transmission assembly to the vehicle.

scientia non olet · About LEMON Manuals