Automatic Transmission: Overhaul Saab 9-2X I

DISASSEMBLY

Note. Do not disassembly the control valve for Saab 9 -2X 2.5i Linear.

Remove oil strainer from lower control valve body.

Note. Arrange the removed bolts in good order to assemble in the same place as disassembly, because the bolt lengths are different.

Scheme 325

1. Short bolt
2. Middle bolt
3. Long bolt

Remove the duty solenoids, solenoids and sensor from the lower valve body.

Note. Arrange the removed bolts in good order to assemble in the same place as disassembly, because the bolt lengths are different.

Scheme 326

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)

Remove the upper-lower valve body tightening bolts.

Note. Arrange the removed bolts in good order to assemble in the same place as disassembly, because the bolt lengths are different.

Scheme 327

Remove the lower valve body.

Remove the oil filter and plate.

Scheme 328

1. Oil filter
2. Plate

Remove six steel balls from middle valve body.

Scheme 329

1. Steel ball
2. Middle valve body

Remove the middle valve body.

Remove upper separator plate from middle valve body.

Scheme 330

1. Upper separator plate
2. Side plate

Remove valve springs and four steel balls from upper valve body.

Place a shop cloth to the piston removal hole.

Using an air compressor, apply air slowly to each piston hole and remove the pistons.

Scheme 331

Remove the seal ring from piston.

Scheme 332

ASSEMBLY

Install a new seal ring to piston.

Scheme 333

Apply ATF to the seal ring.

Insert the piston fully into upper valve body.

Scheme 334

Install the spring and four steel balls to specified positions of upper valve body.

Scheme 335

1. Steel ball
2. Spring

Align the hole in side plate with the hole in separator plate, and then install support plate and upper separator plate to middle valve body.

Tightening torque

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

Scheme 336

1. Upper separator plate
2. Side plate

Insert six steel balls in their proper positions to middle valve body.

Scheme 337

1. Steel ball
2. Middle valve body

Install three filters to lower valve body.

Note. Pay attention to the location of filters.

Scheme 338

1. Strainer
2. Lower valve body

Install the lower separate plate to lower valve body.

Scheme 339

1. Lower separator plate
2. Lower valve body

Temporarily assemble the valve body.

Note. Be careful not to drop the middle valve body and upper body interior steel ball, or the lower body filter.

Scheme 340

Tighten the bolts and nuts.

Note. Install the bolts (D) from upper valve body side.

Tightening torque

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

Scheme 341

Bolt length mm (in)

1. 40 (1.57)
2. 62 (2.44)
3. 73 (2.87)
4. 79 (3.11)

Install the sensor, solenoids and duty solenoids to specified positions.

Scheme 342

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.

Tightening torque

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

Scheme 343

Bolt length mm (in)

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

Install oil strainer to lower valve body.

Tightening torque

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

Scheme 344

Bolt length mm (in)

1. 12 (0.47)
2. 62 (2.44)
3. 81 (3.19)

Remove the seal ring.

Scheme 345

1. Seal ring
2. Transfer clutch

Using a press and ST, remove the ball bearing.

ST 32005091 REMOVER

Scheme 346

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

Scheme 347

1. Snap ring
2. Transfer clutch

Remove the snap ring with ST1, ST2 and ST3, and take out the return spring and transfer clutch piston seal.

ST1 32005082 PLIERS

ST2 32005075 COMPRESSOR

ST3 32005072 SEAT

Scheme 348

1. Snap ring
2. Transfer piston seal

Apply compressed air to the rear drive shaft to remove the piston.

Scheme 349

Install the transfer clutch piston.

Scheme 350

1. Transfer clutch piston
2. Rear drive shaft

Install return spring to transfer piston.

Scheme 351

1. Return spring
2. Rear drive shaft

Apply ATF to the transfer clutch piston seal lip and install it.

Scheme 352

1. Transfer clutch piston seal
2. Rear drive shaft

Install ST to rear drive shaft.

ST 32005128 SNAP RING OUTER GUIDE

Scheme 353

1. Transfer clutch

Install snap ring to ST.

ST 32005128 SNAP RING OUTER GUIDE

Scheme 354

1. Snap ring
2. Transfer clutch

Using ST1 and ST2, install snap ring to rear drive shaft.

ST1 32005128 SNAP RING OUTER GUIDE

ST2 32005127 INSTALLER

Scheme 355

1. Snap ring
2. Transfer clutch

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

Scheme 356

1. Snap ring

Apply compressed air to see if the assembled parts move smoothly

Scheme 357

Check clearance between snap ring and pressure plate.

Press-fit a new ball bearing with ST.

ST 32005175 INSTALLER

Scheme 358

1. Ball bearing

Coat a new seal ring with vaseline, and install it in the seal ring groove of the shaft.

Note. Do not expand the seal ring excessively when installing.

Scheme 359

1. Snap ring
2. Transfer clutch

Install the transfer clutch assembly without damaging seal ring.

Scheme 360

1. Transfer clutch
2. Extension case

Using a press, remove revolution gear.

Scheme 361

1. Revolution gear

Using a press, remove the front and rear side ball bearings and clutch hub.

Scheme 362

1. Rear ball bearing
2. Rear driveshaft
3. Clutch hub

Assemble in the reverse order of disassembly.

Note. Use a new revolution gear and ball bearings. Make sure the clutch hub is oriented in the correct direction.

Scheme 363

1. Front side
2. Clutch hub
3. Rear side
4. Revolution gear

Remove snap ring from reduction driven gear.

Scheme 364

1. Snap ring

Using ST, remove ball bearing from reduction driven gear.

ST 32005091 REMOVER

Scheme 365

1. Ball bearing

Remove snap ring reduction driven gear.

Install snap ring to reduction driven gear.

Using a press, install a new ball bearing to reduction driven gear.

Scheme 366

1. Ball bearing

Install snap ring to reduction driven gear.

Scheme 367

1. Snap ring

Take out the seal rings.

Scheme 368

1. Seal rings
2. Reduction drive shaft

Using ST, remove the ball bearing.

ST 32005091 REMOVER

Scheme 369

1. Ball bearing
2. Reduction drive gear

Using a press, remove the reduction drive gear.

Scheme 370

1. Reduction drive gear

Press-fit the reduction drive gear to the shaft.

Press-fit the a new ball bearing to the reduction drive gear.

Apply vaseline to outer surface of seal ring and shaft groove.

Apply ATF to new seal rings and attach them.

Scheme 371

1. Seal rings
2. Reduction drive shaft

Remove the seal rings.

Scheme 372

1. Seal ring

Using a press and the special tool, remove the ball bearing.

ST 32005091 REMOVER

Scheme 373

Remove the snap ring, and pull out the shaft from the center differential assembly.

Scheme 374

1. Snap ring
2. Shaft

Remove the thrust washers, pinion gears, and washers from the center differential assembly.

Scheme 375

1. Pinion gear

Pull out the intermediate shaft and thrust bearing.

Install the thrust washer onto the intermediate shaft.

Install thrust bearing onto the intermediate shaft.

Install the pinion gears and washers.

Insert the shaft into the center differential assembly.

Install the snap ring.

Using a press, install a new ball bearing into the center differential assembly.

ST 32005088 REMOVER

Scheme 376

1. Plate
2. Center differential carrier

Apply Vaseline onto the seal ring outer surface and shaft grooves.

Apply ATF to new seal rings and install them.

Straighten the staked portion of the lock nut, and remove the lock nut while locking the rear spline portion of the shaft with ST1 and ST2. Then pull off the drive pinion collar.

ST1 32005120 HOLDER

ST2 32005154 WRENCH

ST3 32005153 ADAPTER

Scheme 377

Remove the O-ring.

Using a press, separate the rear roller bearing and outer race from the shaft.

Scheme 378

1. Outer race

Using a press and ST, separate the front roller bearing from the shaft.

ST 32005108 REPLACER

Scheme 379

1. Front roller bearing

Measure dimension "A" of the drive pinion shaft.

ST 32005073 GAUGE

Scheme 380

Using a press, force-fit a new roller bearing in position.

Note. If too much pressure is applied, the roller bearing will not turn easily.

Scheme 381

1. Drive pinion shaft
2. Roller bearing

After fitting a new O-ring to the shaft, attach the drive pinion collar to the shaft.

Install the lock washer to drive pinion shaft in proper direction.

Tighten a new lock nut with ST1, ST2 and ST3.

Calculate lock washer and lock nut specifications using the following formula.

T2 = L2/(L1 + L2) x T1

T1: 116 Nm (11.8 kgf-m, 85.3 ft-lb)

[Required torque setting]

T2: Tightening torque

L1: ST2 length 0.072 m (2.83 in)

L2: Torque wrench length

Example

TIGHTENING TORQUE

ST1 32005120 HOLDER

ST2 32005154 WRENCH

ST3 32005153 ADAPTER

Note. Install ST2 to torque wrench as straight as possible.

Scheme 382

Measure the starting torque of the bearing. Make sure the starting torque is within the specified range. If out of the allowable range, replace the roller bearing.

Starting torque

7.6 - 38.1 N (0.776 - 3.88 kgf, 1.7 - 8.6 lb)

Scheme 383

Stake the lock nut securely at two places.

Measure dimension "B" of the drive pinion shaft.

ST 32005073 GAUGE

Scheme 384

The thickness "t" (mm) of the drive pinion shim.

t = 6.5+/-0.0625 - (B - A)

Select three or less shims from following table.

THICKNESS REFERENCE

DIFFERENTIAL CASE ASSEMBLY

Using a press and ST, remove the taper roller bearing.

ST 32005088 REMOVER

Scheme 385

Secure the case in a vise and remove the hypoid driven gear tightening bolts, then separate the hypoid driven gear, case (RH) and case (LH).

Scheme 386

1. Hypoid driven gear
2. Differential case (RH)
3. Differential case (LH)

Pull out the straight pin and shaft, and remove the differential bevel gear, washer, and differential bevel pinion.

Scheme 387

1. Differential case (RH)

Install the washer, differential bevel gear and differential bevel pinion in the differential case (RH). Insert the pinion shaft.

Install straight pin from reverse direction.

Scheme 388

1. Differential case (RH)

Install the washer and differential bevel gear to the differential case (LH). Then put the case over the differential case (RH), and connect both cases.

Install the hypoid driven gear and secure by tightening the bolt.

Standard tightening torque

62 Nm (6.3 kgf-m, 45.6 ft-lb)

Scheme 389

1. Hypoid driven gear
2. Differential case (RH)
3. Differential case (LH)

Measurement of backlash (Selection of washer)

Install the genuine axle shaft to differential case.

Measure the gear backlash with ST1 and ST2, and insert ST2 through the access window of the case.

ST1 32005094 MAGNET BASE

ST2 32005095 DIAL GAUGE

Note. Measure the backlash by applying a pinion tooth between two bevel gear teeth. Fix bevel pinion gear in place with a screwdriver or similar tool when measuring.

Standard value

0.13 - 0.18 mm (0.0051 - 0.0071 in)

Scheme 390

If backlash is not as specified, select a washer from the table below.

THICKNESS REFERENCE

Using ST, install taper roller bearing.

ST 32005058 DRIFT

Scheme 391

1. Taper roller bearing