Automatic Transmission: Adjustments Saab 9-2X I

ADJUSTMENT

Shift the select lever to "N" range.

Loosen the three inhibitor switch securing bolts.

Insert the ST as vertical as possible into the holes in inhibitor switch lever and switch body.

ST 32005129 STOPPER PIN

Scheme 76

Tighten the three inhibitor switch bolts.

Tightening torque

3.5 Nm (0.35 kgf-m, 2.5 ft-lb)

Repeat the above checks. If the inhibitor switch is determined to be "faulty", replace it.

Remove drive plate and driven plate from center differential carrier.

Using the special tool, measure distance "A" from extension case joining surface to multi -plate clutch (LSD) piston.

ST 32005073 GAUGE

Scheme 77

Scheme 78

1. A: Measured value Using ST, measure height "B" from transmission case joining edge to center differential clutch drum edge. ST 32005076 GAUGE
2. B: Measured value

Calculation formula

T = A - B + 0.45 mm

[T = A - B + 0.0177 in]

Note. Calculation formula for "T" is applied when measuring using ST (32005073 GAUGE, 32005076 GAUGE). When not using ST, apply T = (A - a + 0.45 mm) - (B - b) [T = (A - a + 0.0177 in) - (B - b)]. T: Thrust needle bearing thickness A: Distance from end of extension case to end of reduction drive shaft B: Distance from end of transmission case to end of rear drive shaft a: Collar thickness used when measuring "A" b: Collar thickness used when measuring "B" 0.45: Gasket thickness (mm) Measure multi-plate clutch (LSD) driven and drive plate thickness to find the clearance between measurement value and "T". Standard value: 0.2 - 0.6 mm (0.008 - 0.024 in) Limit value: 1.6 mm (0.063 in) If outside the standard value, replace the plate set (drive and driven plate). Select a multi-plate clutch (LSD) piston side adjustment plate that will bring clearance within the standard value.

THICKNESS REFERENCE

Using ST, measure the distance from the transmission case mating surface to the recessed portion of the high clutch drum "L".

ST 32005073 GAUGE

Scheme 79

Using ST, measure the distance from the oil pump housing mating surface to the top surface of the oil pump cover with thrust needle bearing.

ST 32005073 GAUGE

Scheme 80

Calculation of total end play

Select suitable bearing race from among those listed in this table so that clearance C is in the 0.25 to 0.55 mm (0.0098 to 0.0217 in) range.

C = (L + G) - liters

THICKNESS REFERENCE

Scheme 81

THICKNESS REFERENCE

After completing end play adjustment, insert the bearing race in the recess of the high clutch. Attach the thrust needle bearing to the oil pump cover with vaseline.

After correctly installing the new gasket to the case mating surface, carefully install the oil pump housing assembly. Be careful to avoid hitting the drive pinion against the inside of the case.

Install both parts with dowel pins aligned. Make sure no clearance exists at the mating surface.

Thoroughly remove the liquid gasket from the case mating surface beforehand.

Install the oil pump housing assembly to the converter case, and secure evenly by tightening four bolts.

Note. Use an old gasket or an aluminum washer so as not to damage the mating surface of the housing.

Tightening torque

41 Nm (4.2 kgf-m, 30.4 ft-lb)

Scheme 82

Rotate the drive pinion several times with ST1 and ST2.

ST1 32005120 HOLDER

ST2 32005154 WRENCH

Scheme 83

Adjust the backlash between drive pinion and hypoid driven gear.

Apply red lead evenly to the surfaces of three or four teeth of the hypoid driven gear. Rotate the drive pinion in the forward and reverse directions several times. Then remove the oil pump housing, and check the tooth contact pattern.

If tooth contact is improper, readjust the backlash or shim thickness.

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

1. Tooth contact Checking item : Tooth contact pattern is slightly shifted toward to toe side under no-load rotation. [When loaded, contact pattern moves toward heel.] Toe side Heel side
2. Face contact Checking item: Backlash is too large. Contact pattern Corrective action: Increase thickness of drive pinion height adjusting washer in order to bring drive pinion close to hypoid driven gear.
3. Flank contact Checking item: Backlash is too small. Contact pattern Corrective action: Reduce thickness of drive pinion height adjusting washer in order to move drive pinion away from hypoid driven gear.
4. Toe contact (Inside end contact) Checking item: Contact areas is small Contact pattern Corrective action: Decrease thickness of drive pinion height adjusting washer in order to move drive pinion away from hypoid driven gear.
5. Heel contact (Outside end contact) Checking item: Contact areas is small Contact pattern Corrective action: Increase thickness of drive pinion height adjusting washer in order to move drive pinion close to hypoid driven gear.

If tooth contact is correct, mark the retainer position and loosen it. After fitting a new O-ring and oil seal, screw in the retainer to the marked position. Then tighten the lock plate to the specified torque.

Tightening torque

25 Nm (2.5 kgf-m, 18.1 ft-lb)

Scheme 93

1. Lock plate

Using ST, screw in the retainer until light contact is felt.

Note. Screw in the RH side slightly deeper than the LH side.

ST 32005023 WRENCH ASSY

Scheme 94

Remove the oil pump housing.

Thoroughly remove the liquid gasket from the case mating surface beforehand.

Install the oil pump housing assembly to the converter case, and secure evenly by tightening four bolts.

Note. Use an old gasket or an aluminum washer so as not to damage the mating surface of the housing.

Tightening torque

41 Nm (4.2 kgf-m, 30.4 ft-lb)

Scheme 95

Rotate the drive pinion several times with ST1 and ST2.

ST1 32005120 HOLDER

ST2 32005154 WRENCH

Scheme 96

Tighten the LH retainer until contact is felt while rotating the shaft. Then loosen the RH retainer. Keep tightening the LH retainer and loosening the RH retainer until the pinion shaft can no longer be turned. This is the "zero" state.

Scheme 97

1. Retainer

After the "zero" state is established, back off the LH retainer 3 notches and secure it with the lock plate. Then back off the RH retainer and retighten until it stops. Rotate drive pinion a few times. Tighten the RH retainer 1-3/4 notches further. This sets the preload. Finally, secure the retainer with its lock plate.

Scheme 98

1. Lock plate

Note. Turning the retainer by one tooth changes the backlash about 0.05 mm (0.0020 in).

Scheme 99

Turn the drive pinion several rotations with ST1 and check to see if the backlash is within the standard value with ST2, ST3, ST4 and ST5.

ST1 32005154 WRENCH

ST2 32005094 MAGNET BASE

ST3 32005095 DIAL GAUGE

ST4 32005153 ADAPTER

ST5 32005096 PLATE

Backlash

0.13 - 0.18 mm (0.0051 - 0.0071 in)

Scheme 100

Adjust the tooth contact between front differential and drive shaft.