Automatic Transmission: Other Saab 9-2X I

GENERAL TOOL

GENERAL TOOL

OIL PUMP

OIL PUMP SPECIFICATION

TRANSMISSION CONTROL ELEMENT

TRANSMISSION CONTROL ELEMENT

TRANSMISSION GEAR RATIO

TRANSMISSION GEAR RATIO

PLANETARY GEAR AND PLATE

PLANETARY GEAR AND PLATE

SELECTOR POSITION

SELECTOR POSITION

TRANSFER

TRANSFER REFERENCE

FINAL REDUCTION

FINAL REDUCTION

RECOMMENDED GEAR OIL

RECOMMENDED GEAR OIL

Scheme 435

PRECAUTIONS

1. Wear working clothing, including a cap, protective goggles and protective shoes during operation.
2. Remove contamination including dirt and corrosion before removal, installation, and disassembly.
3. Keep the disassembled parts in order and protect them from dust or dirt.
4. Do not place the oil pan with its inner side facing upward until it is installed so as to prevent foreign matter intrusion into valve body.
5. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
6. When disassembling the case and other light alloy parts, use a plastic hammer to open. Do not pry it apart with a screwdriver or other tool.
7. Be careful not to burn yourself, because each part on the vehicle is hot after running.
8. Use genuine gear oil, grease etc. or the equivalent. Do not mix gear oil, grease etc. with that of another grade or from other manufacturers.
9. Be sure to tighten fasteners including bolts and nuts to the specified torque.
10. Place shop jacks or rigid racks at the specified points.
11. Apply ATF or gear oil onto sliding or revolution surfaces before installation in view of components usage.
12. Replace deformed or otherwise damaged snap rings with new ones.
13. Before installing O-rings or oil seals, apply sufficient amount of ATF to avoid damage and deformation.
14. Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts.
15. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise.
16. Avoid damaging the mating surface of the case.
17. Before applying liquid gasket, completely remove the old seal.

CONDITION CHECK

Note. When replacing ATF, check the inside condition of the transmission body by inspecting the drained ATF.

FLUID CONDITION REFERENCE

GENERAL PRECAUTION

Note. When performing the test, do not exceed posted speed limit.

Road tests should be conducted to properly diagnose the condition of the automatic transmission.

D RANGE SHIFT FUNCTION

Check shifting between 1st ?? 2nd ?? 3rd ?? 4th while driving on normal city streets.

D RANGE SHIFT SHOCK

Check the shock level when shifting up during normal driving.

KICK-DOWN FUNCTION

Check kick-down for each gear. Also check the kick-down shock level.

LOCK-UP FUNCTION

Check that engine speed does not change sharply when the accelerator pedal is lightly depressed when driving on flat roads at normal speed in the D range.

CLIMBING CONTROL FUNCTION

1. Check that the gear remains in 3rd when going up a grade.
2. Check that the gear remains in 3rd when applying the brakes while going down a grade.

TRANSFER CLUTCH

Check if the tight corner braking occurs when the vehicle is started with steering wheel held at fully turned position. (MPT model)

OIL LEAKS

After the driving test, inspect for oil leaks.

MEASUREMENT

Note. If the clutch or the brake shows a sign of slippage or shifting sensation is not correct, the line pressure should be checked. Excessive shocks during upshifting or shifting takes place at a higher point than under normal circumstances, may be due to the line pressure being too high. Slippage or inability to operate the vehicle may, in most cases, be due to loss of oil pressure for the operation of the clutch, brake or control valve.

Line pressure measurement (under no load)

Before measuring the line pressure, jack-up all wheels.

Maintain the temperature of ATF at approx. 70 - 80°C (158 - 176°F) during measurement.

(ATF will reach the above temperature after idling the engine for approx. 30 minutes with select lever in "N" or "P".)

Line pressure measurement (under heavy load)

Before measuring the line pressure, apply both foot and parking brakes with all wheels chocked (Same as for "stall" test conditions).

Measure the line pressure when select lever is in "R" or "2" with engine under stall conditions.

Measure the line pressure within 5 seconds after shifting the select lever to each position. (If line pressure needs to be measured again, allow the engine to idle, and then stop it to cool down for at least one minute.)

Maintain the temperature of ATF at approx. 70 - 80°C (158 - 176°F) during measurement. (ATF will reach the above temperature after idling the engine for approx. 30 minutes with the select lever in "N" or "P".)

Temporarily attach the ST to a suitable place in the driver's compartment, remove the blind plug located in front of the toe board and pass the hose of the ST to engine compartment.

ST 32005111 OIL PRESSURE GAUGE ASSY

Scheme 436

1. Pressure gauge hose
2. Hole in toe board (blank cap hole)
3. Brake pedal

Remove the test plug and install the ST instead.

ST 32005117 OIL PRESSURE GAUGE ADAPTER

Scheme 437

1. Test plug

Connect the ST1 with ST2.

ST1 32005117 OIL PRESSURE GAUGE ADAPTER

ST2 32005111 OIL PRESSURE GAUGE ASSY

Check for duty ratio changes by opening and closing the throttle valve using Vehicle Diagnostic Interface.

1. Saab 9-2X 2.0T Aero PRESSURE REFERENCE Standard line pressure Range position Line pressure duty ratio (%) Throttle position Line pressure kPa (kg/cm 2 , psi) 2 5 Full open 1,128 - 1,304 (11.5 - 13.3, 164 - 189) R 5 Full open 1,520 - 1,716 (15.5 - 17.5, 220 - 249) D 95 Full closed 304 - 412 (3.1 - 4.2, 44 - 60)
2. Saab 9-2X 2.5i Linear PRESSURE REFERENCE Standard line pressure Range position Line pressure duty ratio (%) Throttle position Line pressure kPa (kg/cm 2 , psi) 2 25 - 35 Full open 1,130 - 1,275 (10.2 - 13.3, 145 - 189) R 15 - 25 Full open 1,500 - 1,850 (15.3 - 18.9, 218 - 268) D 35 - 43 Full closed 300 - 400 (5.1 - 8.2, 73 - 116)

Scheme 438

Scheme 439

1. MPT MODEL Check the transfer clutch pressure in accordance with the following chart in the same manner as with line pressure. ST 32005118 OIL PRESSURE ADAPTER SET ST 32005111 OIL PRESSURE GAUGE ASSY AWD mode: "D" range FWD mode: "P" range, engine speed 2,000 RPM NOTE: Before setting in FWD mode, install the spare fuse on FWD switch. Test plug NOTE: If the oil pressure is not produced or if it does not change in the AWD mode, the transfer duty solenoid or transfer valve assembly may be malfunctioning. If the oil pressure is produced in the FWD mode, the problem is similar to that in the AWD mode.
2. VTD MODEL Check transfer clutch pressure using the following chart. ST 32005118 OIL PRESSURE ADAPTER SET ST 32005111 OIL PRESSURE GAUGE ASSY Test plug

STANDARD TRANSFER CLUTCH PRESSURE

1. Saab 9-2X 2.5i Linear PRESSURE REFERENCE Range position ON Duty ratio (%) Acceleration opening angle (%) AWD mode Transfer clutch pressure (kPa (kg/cm 2 , psi)) FWD mode Transfer clutch pressure (kPa (kg/cm 2 , psi)) D 95 100 (Fully opens) 910 - 1,070 (9.3 - 10.9, 132 - 155) - D 60 Adjust ON Duty ratio to 60%. 410 - 490 (4.2 - 5.0, 59 - 71) - N or P 5 0 (Fully closed) 0 - D 5 0 (Fully closed) - 0
2. Saab 9-2X 2.0T Aero PRESSURE REFERENCE Range position ON Duty ratio (%) Acceleration opening angle (%) AWD mode Transfer clutch pressure (kPa (kg/cm 2 , psi)) 2 95 100 (Fully opens) 1,000 - 1,200 (10.2 - 12.2, 145 - 174) 2 60 Adjust ON Duty ratio to 60%. 500 - 700 (5.1 - 7.1, 72.5 - 102) N or P 5 0 (Fully closed) 0

PITCHING STOPPER

Disconnect the ground cable from battery.

Remove the air intake chamber. (Saab 9-2X 2.5i Linear)

Remove intercooler. (Saab 9-2X 2.0T Aero)

Remove the pitching stopper.

Scheme 440

TRANSMISSION REAR CROSSMEMBER AND REAR CUSHION RUBBER

Disconnect the ground cable from battery.

Jack-up the vehicle and support it with sturdy racks.

Remove the front, center, rear exhaust pipes and muffler. (Saab 9-2X 2.5i Linear)

Remove center and rear exhaust pipes, and muffler. (Saab 9-2X 2.0T Aero)

Remove the heat shield cover. (If equipped)

Set the transmission jack under the transmission. Make sure that the support plates of transmission jack don't touch the oil pan.

Remove the transmission rear crossmember.

Scheme 441

Remove the rear cushion rubber.

Install the pitching stopper.

Tightening torque

T1: 50 Nm (5.1 kgf-m, 37 ft-lb)

T2: 58 Nm (5.9 kgf-m, 43 ft-lb)

Scheme 442

Install the air intake chamber. (Saab 9-2X 2.5i Linear)

Remove intercooler. (Saab 9-2X 2.0T Aero)

Install the rear cushion rubber.

Tightening torque

39 Nm (4.0 kgf-m, 29 ft-lb)

Install the crossmember.

Tightening torque

T1: 35 Nm (3.6 kgf-m, 26 ft-lb)

T2: 70 Nm (7.1 kgf-m, 51 ft-lb)

Scheme 443

Remove the transmission jack.

Install the heat shield cover. (If equipped)

Install the front, center, rear exhaust pipes and the muffler. (Saab 9-2X 2.5i Linear)

Install center and rear exhaust pipes, and muffler. (Saab 9-2X 2.0T Aero)

Make sure that the pitching stopper is not bent or damaged. Make sure that the rubber is not stiff, cracked, or otherwise damaged.

Make sure that the crossmember is not bent or damaged. Make sure that the cushion rubber is not stiff, cracked, or otherwise damaged.

VTD MODEL

When removing the rear vehicle speed sensor, refer to " FRONT VEHICLE SPEED SENSOR ".

MPT MODEL

Set the vehicle on a lift, and then lift-up the vehicle.

Disconnect the connector from rear vehicle speed sensor.

Scheme 444

1. Rear vehicle speed sensor

Remove the rear vehicle speed sensor.

Scheme 445

When installing the rear vehicle speed sensor, refer to " FRONT VEHICLE SPEED SENSOR ".

Install in the reverse order of removal.

Note. Replace with a new O-ring.

Tightening torque

7 Nm (0.7 kgf-m, 5.1 ft-lb)

PROCEDURE

Note. Do not bleed air of control valve for Saab 9 -2X 2.0T Aero.

Set the select lever to "P" range and apply parking brake, then lift-up the vehicle.

Connect the Vehicle Diagnostic Interface to vehicle.

Using Vehicle Diagnostic Interface, check that the DTC is not output.

Using Vehicle Diagnostic

SHIFT SOLENOIDS AND DUTY SOLENOIDS

Lift-up the vehicle.

Clean the transmission exterior.

Replace the gasket with a new one, and tighten the drain plug.

Drain the ATF completely.

Tightening torque

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

Scheme 446

1. Oil pan
2. Drain plug (ATF)
3. Differential gear oil drain plug

Remove the oil pan.

Disconnect the solenoid and duty solenoid connectors.

Scheme 447

1. Lock-up duty solenoid (Blue)
2. Low clutch timing solenoid (Gray)
3. Line pressure duty solenoid (Red)
4. Shift solenoid 2 (Yellow)
5. Shift solenoid 1 (Green)
6. 2-4 brake timing solenoid (Black)
7. 2-4 brake duty solenoid (Red)
8. Transfer duty solenoid (Brown)

Remove the solenoids and duty solenoids.

Scheme 448

1. Lock-up duty solenoid (Blue)
2. Low clutch timing solenoid (Gray)
3. Line pressure duty solenoid (Red)
4. Shift solenoid 2 (Yellow)
5. Shift solenoid 1 (Green)
6. 2-4 brake timing solenoid (Black)
7. 2-4 brake duty solenoid (Red)

ATF TEMPERATURE SENSOR

For removal of ATF temperature sensor, refer to " FRONT VEHICLE SPEED SENSOR ".

Insert solenoid and duty solenoid to specified position.

Scheme 449

1. Lock-up duty solenoid (Blue)
2. Low clutch timing solenoid (Gray)
3. Line pressure duty solenoid (Red)
4. Shift solenoid 2 (Yellow)
5. Shift solenoid 1 (Green)
6. 2-4 brake timing solenoid (Black)
7. 2-4 brake duty solenoid (Red)

Tighten the bolts and nuts.

Tightening torque

8 Nm (0.8 kgf-m, 5.8 ft-lb)

Scheme 450

Bolt length mm (in)

1. 12 (0.47)
2. 40 (1.57)
3. 45 (1.77)
4. 62 (2.44)
5. 73 (2.87)

Connect the harness connectors.

Connect the connectors of same color, and secure the harness to valve body using clips.

Scheme 451

1. Lock-up duty solenoid (Blue)
2. Low clutch timing solenoid (Gray)
3. Line pressure duty solenoid (Red)
4. Shift solenoid 2 (Yellow)
5. Shift solenoid 1 (Green)
6. 2-4 brake timing solenoid (Black)
7. 2-4 brake duty solenoid (Red)
8. Transfer duty solenoid (Brown)

Apply proper amount of liquid gasket to the entire oil pan mating surface.

Fluid packing

THREE BOND 1217B (Part No. 32005004)

Scheme 452

Apply liquid gasket fully to three holes other than screw holes on transmission case.

Fluid packing

THREE BOND 1217B (Part No. 32005004)

Scheme 453

Install the oil pan.

Tightening torque

5 Nm (0.5 kgf-m, 3.6 ft-lb)

Fill ATF up to the middle of the "COLD" side on level gauge by using the gauge hole.

Check the ATF level.

ATF TEMPERATURE SENSOR

For installation of ATF temperature sensor, refer to " FRONT VEHICLE SPEED SENSOR ".

Take out the transfer clutch by lightly tapping the end of the rear drive shaft.

Note. Be careful not to damage the oil seal in the extension.

Scheme 454

1. Transfer clutch
2. Extension case

Remove the transmission clutch pipe without deforming pipe.

Scheme 455

1. Extension case
2. Transfer clutch pipe

Remove snap ring using ST1, ST2, ST3 and a press.

ST1 32005075 COMPRESSOR

ST2 32005112 SEAT

ST3 32005074 PLIERS

Scheme 456

Remove test plug.

Scheme 457

1. Test plug
2. Extension case

Remove clutch piston using compressed air.

Scheme 458

Pay attention, not to deform pipe, and remove transfer clutch pipe.

Scheme 459

Remove the dust cover from the extension case.

Remove the oil seal from the extension case.

Using the ST and a press, press in a new oil seal.

ST 32005087 INSTALLER

Press in the dust cover.

Install the transfer clutch pipe to extension case without deforming pipe.

Scheme 460

1. Extension case
2. Transfer clutch pipe

Install the transfer clutch assembly to the case.

Note. Be careful not to damage the seal rings. Insert the clutch assembly fully into position until the bearing shoulder bottoms.

Scheme 461

1. Transfer clutch
2. Extension case

Press new oil seal using ST and a press.

ST 32005087 INSTALLER

Press dust cover.

Install the transfer clutch pipe onto the extension case, taking care not to deform the pipe.

Scheme 462

Apply ATF to new O-ring and install the test plug.

Tightening torque

13 Nm (1.3 kgf-m, 9.4 ft-lb)

Scheme 463

1. Test plug
2. Extension case

Insert the multi-plate clutch, drive plates, driven plates, and spring retainer.

Scheme 464

1. Spring retainer
2. Multi-plate clutch (LSD) piston assembly

Install the snap ring using special tools 1, 2, and 3.

ST1 32005075 COMPRESSOR

ST2 32005112 SEAT

ST3 32005074 PLIERS

Scheme 465

Measure distance "A" from end of extension case and rear drive shaft with ST.

ST 32005073 GAUGE

Scheme 466

Scheme 467

1. A: Measured value Measure the distance "B" from the transmission case mating surface to the reduction drive gear end surface with ST1 and ST2. ST1 32005073 GAUGE ST2 32005133 GAUGE
2. B: Measured value

Calculation formula

Note. Calculate "T": T = A - B + 35.4 mm [T = A - B + 1.3937 in] T: Thrust needle bearing thickness A: Distance from end of extension case to end of rear drive shaft B: Distance from end of transmission case to end of reduction drive gear Example: When, A = 33.6 mm (1.3228 in), B = 65.05 mm (2.5610 in) T = 33.6 - 65.05 + 35.4 = 3.95 [T = 1.3228 - 2.5610 + 1.3937 = 0.1555] After calculation, the valve of "H" becomes 3.95 mm (0.1555 in), therefore select bearing thickness of 3.8 mm (0.150 in). Calculation formula for "T" is applied when measuring using ST (32005073 GAUGE, 32005133 GAUGE). When not using ST, apply T = (A - a + 0.45 mm) - (B - ) - H [T = (A - a + 0.0177 in) - (B - ) - H]. 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 (0.0177): Gasket thickness (mm (in)) H: Shim clearance

THICKNESS REFERENCE

VID MODEL

Insert the rear driveshaft into the reduction drive gear and center differential assembly.

Scheme 468

1. Rear drive shaft
2. Center differential carrier

Using the special tool, measure the distance "A" between the mating surface of extension case and multi-plate clutch (LSD) piston.

ST 32005073

Scheme 469

Scheme 470

1. A: Measured value Using the ST, measure the distance "B" between the mating surface of transmission case and reduction drive gear edge. ST 32005073 GAUGE
2. B: Measured value

Formula

Note. Calculation of "T": When clearances are 0.05 mm (0.0020 in), select up to four adjusting shims from the table, suitable for clearance value. When clearances are 0.05 mm (0.0020 in) T = A - B + 0.40 mm [T = A - B + 0.0157 in] When clearances are 0.25 mm (0.0098 in) T = A - B + 0.20 mm [T = A - B + 0.0079 in] T: Shim clearance A: Distance between extension case edge and rear driveshaft edge B: Distance between transmission case edge and reduction drive gear edge T: Shim thickness 0.05 - 0.25 mm (0.0020 - 0.0098 in) Example: When, A = 90.50 mm (3.5630 in), B = 90.35 mm (3.5571 in) Calculation for 0.05 mm (0.0020 in) of clearance T = 90.50 - 90.35 + 0.4 = 0.55 [T = 3.5630 - 3.5571 + 0.0157 = 0.0216] Calculation when clearance is 0.25 mm (0.0098 in) T = 90.50 - 90.35 + 0.2 = 0.35 [T = 3.5630 - 3.5571 + 0.0079 = 0.0138] Calculation formula for "T" is applied when measuring using ST (32005073 GAUGE). When not using ST, apply T = (A - a + 0.45 mm) - (B - ) - H [T = (A - a + 0.0177 in) - (B - ) - H]. T: Thrust needle bearing thickness A: Distance from end of extension case to rear drive shaft ball bearing outer ring contact surface B: Distance from end of transmission case to end of rear drive shaft ball bearing a: Collar thickness used when measuring "A" b: Collar thickness used when measuring "B" 0.45: Gasket thickness (mm) H: Shim clearance After calculation, the value of "T" becomes between 0.35 mm (0.0138 in) and 0.55 mm (0.0216 in), therefore select two shims with thickness of 0.2 mm (0.010 in) or one shim with thickness of 0.5 mm (0.020 in).

THICKNESS REFERENCE

Remove the transmission assembly from the vehicle.

Remove rear vehicle speed sensor, and separate the transmission case and extension case.

Set the range select lever to "P".

Straighten the staked portion, and remove the lock nut.

Scheme 471

1. Reduction driven gear
2. Reduction drive gear

Using the ST1 and ST2, extract the reduction driven gear.

ST1 32005144 PULLER

ST2 32005174 PULLER SET

Scheme 472

1. Reduction driven gear
2. Reduction drive gear

Remove the transmission assembly from the vehicle.

Remove rear vehicle speed sensor, and separate the transmission case and extension case.

Remove the rear drive shaft.

Set the range select lever to "P".

Straighten the staked portion, and remove the lock nut.

Scheme 473

Using the ST1 and ST2, extract the reduction driven gear.

ST1 32005144 PULLER

ST2 32005174 PULLER SET

Pull out the center differential assembly.

Set the select lever to "P" range.

Using a plastic hammer, install reduction driven gear assembly and new washer, and tighten new drive pinion lock nut.

Tightening torque

100 Nm (10.2 kgf-m, 73.8 ft-lb)

Scheme 474

1. Reduction driven gear
2. Reduction drive gear

After tightening, stake the lock nut securely.

Combine the transmission case with the extension case, and install rear vehicle speed sensor.

Install the transmission assembly to vehicle.

Set the select lever to "P" range.

Using a plastic hammer, install reduction driven gear assembly.

Using a plastic hammer, install the center differential assembly.

Install a new self-lock nut and a washer.

Tightening torque

100 Nm (10.2 kgf-m, 73.8 ft-lb)

Scheme 475

After tightening, stake the lock nut securely.

Insert the rear drive shaft assembly.

Combine the transmission case with the extension case, and install rear vehicle speed sensor.

Install the transmission assembly to vehicle.

OIL PUMP COVER

Remove four seal rings.

Scheme 476

1. Seal rings

Lightly tap the end of the stator shaft to remove the cover.

Scheme 477

1. Oil pump cover
2. Oil pump housing

Remove the inner and outer rotor.

Scheme 478

1. Inner rotor
2. Outer rotor

OIL SEAL RETAINER

Remove the oil seal retainer.

Scheme 479

1. Oil seal retainer
2. Drive pinion shaft

Remove the O-ring.

Scheme 480

1. O-ring

Remove the oil seal from oil seal retainer.

Scheme 481

1. Oil seal
2. Oil seal retainer

Install oil pump rotor assembly to oil pump housing.

Scheme 482

1. Inner rotor
2. Outer rotor

Align both pivots with the pivot holes of the cover, and install the oil pump cover being careful not to apply undue force to the pivots.

Tightening torque

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

Scheme 483

1. Oil pump cover
2. Oil pump housing

After assembling, turn the oil pump shaft to check for smooth rotation of the rotor.

Install the oil seal retainer and new seal rings. After adjusting the drive pinion backlash and tooth contact.

Scheme 484

1. Seal rings (Black)
2. Seal rings (Brown)

Install two new oil seals to the oil seal retainer in proper position using ST.

ST 499247300 INSTALLER

Scheme 485

1. Oil seal
2. Oil seal retainer

Install a new O-ring to the oil seal retainer using vaseline. Install the seal to oil pump housing bore.

Scheme 486

1. O-ring

Install the oil seal and secure it using three bolts being careful not to damage oil seal lip.

Tightening torque

7 Nm (0.7 kgf-m, 5.1 ft-lb)

Scheme 487

1. Oil seal retainer
2. Drive pinion shaft

SIDE RETAINER

Note. After adjusting the drive pinion backlash and tooth contact, remove and install the oil seal and O-ring.

Remove O-ring.

Scheme 488

Remove oil seal.

Scheme 489

Take out either split pin, remove claw.

ST 32005071 PULLER ASSY

Scheme 490

1. Claw
2. Split pin
3. Pin

Securely attach two claws to outer race, set ST to side retainer.

ST 32005071 PULLER ASSY

Scheme 491

1. Shaft
2. Claw

Return removed claw to the original position, and install pin and split pin.

Hold the shaft of ST to avoid removing from side retainer, and then remove the bearing outer race.

ST 32005071 PULLER ASSY

Note. Replace bearing inner and outer races as a single unit.

Scheme 492

1. Shaft
2. Side retainer

Install bearing outer race to side retainer.

Install a new oil seal using the ST and hammer.

ST 32005024 DIFFERENTIAL SIDE OIL SEAL INSTALLER

Scheme 493

Apply gear oil to new O-ring and install it.

Scheme 494

HIGH CLUTCH, REVERSE CLUTCH

Remove the snap ring, and take out the retaining plate, drive plates, driven plates.

Scheme 495

1. Snap ring

Remove snap ring, and take out the retaining plate, drive plates and driven plates.

Scheme 496

1. Snap ring

Using ST1 and ST2, remove snap ring.

ST1 32005075 COMPRESSOR

ST2 32005112 SEAT

Scheme 497

1. Snap ring

Take out clutch cover, spring retainer, high clutch piston and reverse clutch piston.

Scheme 498

1. Reverse clutch piston
2. Cover
3. Return spring

Remove seal rings and lip seal from high clutch piston and reverse clutch piston.

Scheme 499

1. High clutch piston
2. Reverse clutch piston

PLANETARY GEAR, LOW CLUTCH

Remove snap ring from the low clutch drum.

Scheme 500

1. Snap ring
2. Low clutch drum

Take out front planetary carrier.

Scheme 501

1. Front planetary carrier
2. Low clutch drum

Take out rear sun gear.

Scheme 502

1. Rear sun gear
2. Rear planetary carrier

Take out rear planetary carrier, washer and thrust needle bearing.

Scheme 503

1. Rear planetary carrier
2. Low clutch drum

Take out rear internal gear.

Scheme 504

1. Rear internal gear
2. Low clutch drum

Remove the snap ring from the low clutch drum.

Scheme 505

1. Snap ring
2. Low clutch drum

Compress the spring retainer, and remove the snap ring from the low clutch drum, by using ST1 and ST2.

ST1 32005112 SEAT

ST2 32005075 COMPRESSOR

Scheme 506

1. Snap ring
2. Low clutch drum

Remove one-way clutch.

Install the one-way clutch inner race to the low clutch drum, and apply compressed air to remove the low clutch piston.

Scheme 507

1. Apply compressed air
2. One-way clutch inner race

Remove the one-way clutch inner race.

Remove the one-way clutch after taking out the snap ring.

Scheme 508

1. Snap ring
2. Plate
3. One-way clutch

Remove the needle bearing after taking out the snap ring.

Scheme 509

1. Needle bearing
2. Snap ring

2-4 BRAKE

Separate 2-4 brake piston and piston retainer.

Scheme 510

1. 2-4 brake piston
2. 2-4 brake piston retainer

Remove the D-ring from 2-4 brake piston.

ONE-WAY CLUTCH OUTER RACE

Remove seal rings.

Scheme 511

1. One way clutch inner race
2. Seal rings

Using ST, remove needle bearing.

ST 32005071 PULLER ASSY

ONE-WAY CLUTCH INNER RACE

Remove the one-way clutch after taking out the snap ring.

Scheme 512

1. Snap ring
2. Plate
3. One-way clutch

Remove the needle bearing after taking out the snap ring.

Scheme 513

1. Needle bearing
2. Snap ring

Install seal rings and lip seal to high clutch piston and reverse clutch piston.

Install high clutch piston to reverse clutch piston.

Scheme 514

1. High clutch piston
2. Reverse clutch piston

Install reverse clutch to high clutch drum.

Align the groove on the reverse clutch piston with the groove on the high clutch drum during installation.

Scheme 515

1. Reverse clutch piston
2. High clutch drum

Install spring retainer to high clutch piston.

Scheme 516

1. Return spring
2. High clutch drum

Install ST to high clutch piston.

ST 32005102 HIGH CLUTCH PISTON GUIDE

Scheme 517

Avoid folding the high clutch piston seal, when installing the cover to high clutch piston.

Using ST1 and ST2, install snap ring.

ST1 32005075 COMPRESSOR

ST2 32005112 SEAT

ST3 32005102 HIGH CLUTCH PISTON GUIDE

Scheme 518

Selection of high clutch retaining plate (Saab 9-2X 2.0T Aero)

Install the thickest driven plate to piston side, and then install the driven plate, drive plate, retaining plate to high clutch drum.

Scheme 519

Install snap ring to high clutch drum.

Apply compressed air intermittently to check for operation.

Scheme 520

Measure the clearance between the retaining plate and snap ring. (High clutch) At this time, do not press down retaining plate.

Initial standard

0.8 - 1.1 mm (0.031 - 0.043 in)

Limit thickness

1.5 mm (0.059 in)

Scheme 521

1. Thickness gauge

If specified tolerance limits are exceeded, select a suitable high clutch retaining plate. If it exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.

THICKNESS REFERENCE

Selection of high clutch 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 250 N (25.5 kgf, 56.2 lb).

Put the flat board on retaining plate.

Scheme 522

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

N = 250 N (25.5 kgf, 56.2 lb) - Z

N: Value indicated on push/pull gauge

250 N (25.5 kgf, 56.2 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°.

Scheme 523

1. Driven plate
2. Drive plate
3. Retaining plate

Install the thickest driven plate to piston side, and then install the driven plate, drive plate, retaining plate to high clutch drum.

Scheme 524

Install the snap ring to high clutch drum.

Apply compressed air intermittently to check for operation.

Scheme 525

Measure and record the clearance B between the retaining plate and snap ring. (High clutch)

At this time, do not press down the retaining plate.

Scheme 526

1. Thickness gauge

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

2.0 - 2.3 mm (0.079 - 0.091 in)

Limit thickness

2.6 mm (0.102 in)

THICKNESS REFERENCE

Selection of reverse clutch retaining plate (Saab 9-2X 2.0T Aero)

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

Scheme 527

Apply compressed air intermittently to check for operation.

Scheme 528

Measure the clearance between the retaining plate and snap ring. (Reverse clutch) At this time, do not press down retaining plate.

Initial standard

0.5 - 0.8 mm (0.020 - 0.031 in)

Limit thickness

1.2 mm (0.047 in)

Scheme 529

1. Thickness gauge

If specified tolerance limits are exceeded, select a suitable high clutch retaining plate.

If it exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.

THICKNESS REFERENCE

Selection of reverse clutch 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 150 N (15.3 kgf, 33.7 lb).

Put the flat board on retaining plate.

Scheme 530

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

N = 150 N (15.3 kgf, 33.7 lb) - Z

N: Value indicated on push/pull gauge

150 N (15.3 kgf, 33.7 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°.

Scheme 531

1. Driven plate
2. Drive plate
3. Retaining plate

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

Scheme 532

Apply compressed air intermittently to check for operation.

Scheme 533

Measure and record the clearance B between the retaining plate and snap ring. (Reverse clutch)

At this time, do not press down the retaining plate.

Scheme 534

1. Thickness gauge

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 specification.

T = A + B

T: Piston stroke

A: Collapse amount of drive plate

B: Clearance between retaining plate and snap ring

Initial standard

1.1 - 1.4 mm (0.043 - 0.055 in)

Limit thickness

1.6 mm (0.063 in)

THICKNESS REFERENCE

Install D-ring to low clutch piston.

Fit the low clutch piston to the low clutch drum.

Scheme 535

1. Low clutch piston
2. Low clutch drum

Install spring retainer to low clutch piston.

Scheme 536

1. Spring retainer
2. Low clutch drum

Install ST to low clutch drum.

ST 32005103 LOW CLUTCH PISTON GUIDE

Scheme 537

Set the cover on the piston with a press using ST1 and ST2, and attach the snap ring. At this time, be careful not to fold cover seal during installation.

ST1 32005112 SEAT

ST2 32005075 COMPRESSOR

ST3 32005103 LOW CLUTCH PISTON GUIDE

Scheme 538

Install the dish plate, driven plates, drive plates, and retaining plate, and secure with the snap ring.

Scheme 539

1. Snap ring
2. Low clutch drum
3. Dish plate
4. Low clutch piston side

Check the low clutch for operation.

Remove one-way clutch.

Set the one-way clutch inner race, and apply compressed air for checking.

Scheme 540

1. Apply compressed air
2. Low clutch drum

Checking low clutch clearance.

Place the same thickness of shim on both sides to prevent retaining plate from tilting.

Inspect clearance between retaining plate and operation of the low clutch.

Initial standard

0.7 - 1.1 mm (0.028 - 0.043 in)

Limit thickness

1.6 mm (0.063 in)

Scheme 541

1. Thickness gauge
2. Low clutch drum

If the clearance is out of the specified range, select a proper retaining plate so that the standard clearance can be obtained.

If it exceeds the service limit, replace the drive plate with a new one and adjust it to the specification.

THICKNESS REFERENCE

Install washer to rear internal gear.

Scheme 542

1. Rear internal gear
2. Washer

Install rear internal gear.

Scheme 543

1. Rear internal gear
2. Low clutch drum

Install thrust needle bearing in the correct direction.

Scheme 544

1. Thrust needle bearing
2. Low clutch drum

Install the washer by aligning protrusion of washer and hole of rear planetary carrier.

Scheme 545

1. Washer
2. Rear planetary carrier

Install rear planetary carrier to low clutch drum.

Scheme 546

1. Rear planetary carrier
2. Low clutch drum

Install thrust needle bearing in the correct direction.

Scheme 547

Install the rear sun gear in proper direction.

Scheme 548

1. Rear sun gear
2. Rear planetary carrier

Install the thrust needle bearing in proper direction.

Scheme 549

1. Thrust needle bearing
2. Front planetary carrier
3. Rear sun gear side
4. Front planetary carrier side

Install front planetary carrier to low clutch drum.

Scheme 550

1. Front planetary carrier
2. Low clutch drum

Install snap ring to low clutch drum.

Scheme 551

1. Snap ring
2. Front planetary carrier

Install the needle bearing, and secure with the snap ring.

Scheme 552

1. Needle bearing
2. Snap ring

Install the one-way clutch, one-way clutch inner race and plate, and secure with the snap ring.

Set the inner race. Make sure that the clutch is locked in the clockwise direction and free in the counterclockwise direction.

Scheme 553

1. Locked
2. Free

Apply ATF to new D-ring, and install it to 2-4 brake piston.

Install 2-4 brake piston to 2 -4 brake piston retainer.

Scheme 554

1. 2-4 brake piston
2. 2-4 brake piston retainer

Using a press and ST, install the needle bearing to the inner race.

ST 32005065 INSTALLER

Scheme 555

Apply vaseline to the groove of the inner race and to the seal ring.

Install two seal rings to one-way clutch inner race.

Scheme 556

1. One way clutch inner race
2. Seal rings

Install the needle bearing, and secure with the snap ring.

Scheme 557

1. Needle bearing
2. Snap ring

Install the one-way clutch, one-way clutch inner race and plate, and secure with the snap ring.

Set the inner race. Make sure that the clutch is locked in the clockwise direction and free in the counterclockwise direction.

Scheme 558

1. Locked
2. Free

HIGH CLUTCH AND REVERSE CLUTCH

Inspect the following items.

1. Drive plate facing for wear and damage
2. Discoloration of driven plate (Burnt color)
3. Snap ring for wear, return spring for setting and breakage, and snap ring retainer for deformation
4. Lip seal and D-ring for damage
5. Piston and drum check ball for operation
6. Adjust total end play.

PLANETARY GEAR AND LOW CLUTCH

Inspect the following items.

1. Drive plate facing for wear and damage
2. Discoloration of driven plate (Burnt color)
3. Snap ring for wear, return spring for breakage or setting, and spring retainer for deformation
4. Lip seal and D-ring for damage
5. Piston check ball for operation
6. Measure the total end play and adjust to within specifications.

Inspect the following items.

1. Drive plate facing for wear and damage
2. Discoloration of driven plate (Burnt color)
3. Snap ring for wear and spring retainer for deformation
4. Lip seal and D-ring for damage
5. Measure the total end play and adjust to within specifications.

ONE-WAY CLUTCH

1. Make sure the snap ring is not worn and the seal rings are not damaged.
2. Measure the total end play and adjust to within specifications.

LOW & REVERSE BRAKE

Check for the following.

1. Drive plate facing for wear or damage
2. Discoloration of driven plate (Burnt color)
3. Snap ring for wear and spring retainer for deformation