Transaxle Reassembly

NOTE: Handle all parts carefully to avoid damaging bearing and mating surfaces. Lubricate all components with ATF. Use petroleum jelly to hold gaskets and thrust washers in place. Ensure thrust washers and bearings are installed in correct locations. See Fig 1 .

Blow out ventilation channels with compressed air. Install pinion bearing housing locating studs into case. Install pinion bearing shims. Lubricate bearing housing sealing rings.

NOTE: Pinion depth must be measured using Saab Measuring Instrument (83 90 155). See Fig 2 .

Position complete pinion bearing housing assembly on locating stubs. Place case in press, and press in housing. Press bearing housing in as far as it will go. Remove locating studs and install retaining bolts. Check pinion clearance.
To calibrate indicator, place calibration stops of measuring tool against gauge block. Distance between stops and centerline of tool is 2.362" (60.00 mm), which is equal to distance from end face of pinion shaft to centerline 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 a permitted tolerance of .002" (.05 mm). For example, if pinion is stamped +3, indicator should read +3 plus or minus .05 mm. See Fig 3 .
If measured pinion depth reading is not within specifications (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 specifications, 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).
Before reinstalling pinion housing and pinion depth adjusting shims, differential bearing preload must be adjusted. Place differential/final drive, assembly into transaxle case. Install left side inner drive shaft housing (side with speedometer drive) without shims.
Install attaching bolts and tighten to 15-18 ft. lbs. (20-25 N.m). Oil differential bearing, and install right side drive shaft housing without shims. Tighten attaching bolts to 19 INCH lbs. (2.2 N.m) in 2 or 3 steps. Rotate differential assembly while tightening bolts.

NOTE: Up to 4 shims may be used to obtain correct preload. Adjusting shims are available in thicknesses of .004" (.15 mm), .012" (.30 mm) and .020" (.50 mm)

Using a feeler gauge, measure gap between right side drive shaft housing and transaxle case at 2 points opposite each other. See Fig 4 . Take average of 2 readings and select adjusting shims which will equal this value. Then add an additional .008" (.20 mm) in shim thickness to obtain correct bearing preload.
Remove right side drive shaft housing and lift out differential/final drive assembly. Reinstall pinion shaft housing along with pinion depth adjusting shims. Recheck pinion depth adjustment. Reinstall differential/final drive assembly.
Reinstall right side drive shaft housing along with previously selected bearing preload adjusting shims and tighten attaching bolts. Grease sealing rings on output shaft. Place transaxle housing in vise and support pinion with a drift.
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. Measure assembly depth in case with a large depth gauge. Total depth should be 7.561-7.576" (192.04-192.48 mm) including shims. See Fig 5 .
If parking pawl was removed during disassembly, reverse removal procedure to install. Grease front and rear servo piston "O" rings. Install pistons into servo cylinders in transaxle case.

NOTE: Soak brake bands (front and rear) in ATF prior to installation.

Install rear brake band. Install thrust bearing, race and shims in planetary gear assembly. Install planetary gear and center support. Install front brake band.
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 properly with planetary gear.
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 6 .
Place pin in rear servo piston. Place to band apply strut against rear band. Place rear band apply lever in position and insert shaft from side until it protrudes approximately .04" (10 mm).

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 shafts Place short strut against front band. Place lever in position and press in lever shaft from side.
Grease transaxle housing-to-torque converter housing mating surface. Install gasket to transaxle housing. Grease 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.
Hold parking pawl out of way with a screwdriver. Place gear selector lever in transaxle case. Guide front servo oil tube into position while installing torque converter housing-to-transaxle case. Install converter housing-to-transaxle case attaching bolts. Pull converter housing into position with bolts.
Check transaxle gear unit end play. See Fig 7 . Mount a dial indicator on torque converter housing, so that 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 .01-.03" (.25-.75 mm). If end play is not to specifications, adjust by adding or removing shims between thrust washer and front bearing.
Install accumulator piston. Place valve body assembly into converter housing and ensure that manual gear selector is properly connected. Center valve body in position with 5 retaining bolts, tighten 2 and remove others. See Fig 8 . Attach cam disc cable to cam disc on valve body. Check that cable is positioned in pulley groove.
Install oil tubes in order. See Fig 9 . Tubes No. 16 and 17 should have been installed with drain valve. When installing tube No. 12, run it under tube No. 9 and install tube support (if equipped). Install oil strainer and magnet. Install connection pipes.
To adjust rear band, locate adjusting screw on outer left side of transaxle case. Loosen adjusting screw. Tighten screw to 10 ft. lbs. (14 N.m). Back adjusting screw off one turn, and tighten lock nut.
To adjust front band, loosen lock nut. See Fig 10 . Place Spacer (87 90 030), or 11/32" (8.9 mm) rod, between screw and piston pin. Tighten adjusting screw to 12 INCH lbs. (1.3 N.m). Remove spacer. Hold adjusting screw so it does not move, and tighten lock nut.
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. Install turbine shaft seal. Install differential assembly and bearing housing. Install complete shim pack under right bearing seat.

NOTE: Backlash with a new ring and pinion set (or a used set with less than 6000 miles service) should to specification which appears on ring gear. See Fig 11 . If used gear set it more than 6000 miles service is being reinstalled, backlash should be same as was recorded during transaxle disassembly.

To check ring gear backlash, mount dial indicator on transaxle case so that indicator tip is touching ring gear teeth. See Fig 12 . Measure backlash. Check backlash at 4 different points around ring gear. Measurements must not vary by more than .002" (.05 mm) from specifications.
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.