Automatic Transmission - 9-5: Specifications Saab 9-5 I рестайлинг

Gear Case and torque converter shell

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1. Drain the oil from the transmission in the car before starting removal. Remove the «GEARBOX»(ref-212247-S04337975522005122300000) from the car. See removing gearbox assembly. Fit the dipstick pipe.
2. Plug the shaft openings. Clean the exterior of the gearbox. Use plug 91 32 929, seals 91 32 937 and «87 92 665 PROTECTIVE PLUG, DRIVE SHAFT HOLE»(ref-212247-S22817548852005122300000) . Plug the vent pipe.
3. Unplug the connectors and remove the wiring harness.
4. Remove the dipstick pipe.
5. Fit holder «87 92 392 HOLDER, TRANSMISSION»(ref-212247-S40767173122005122300000) on the gearbox using flange screw M8x25. NOTE: Organize the workplace so that groups of associated parts that are dismantled can be kept together to facilitate refitting.
6. Mount the gearbox in stand «78 74 878 FLOOR STAND»(ref-212247-S29669990032005122300000) .
7. Bend out the lock washer for the gear position sensor nut and loosen the nut slightly.
8. Remove the gear position sensor.
9. Unplug the connectors to the speed sensors and the temperature sensor. Remove the speed sensors.
10. Fit tool «87 91 766 GRIPPING TOOL, TORQUE CONVERTER»(ref-212247-S17527409822005122300000) into the torque converter. Remove holder «87 92 574 HOLDER»(ref-212247-S03891516862005122300000) . Remove the torque converter.
11. Turn the gearbox through 180 ° in the stand.
12. Remove the cover plate and the temperature sensor.
13. Remove the plate cover on the torque converter shell.
14. Remove the bolts securing the valve body cover and knock loose the cover using a splinter-free plastic mallet. IMPORTANT: Take care that the sealing surfaces are not damaged.
15. Disconnect the solenoid electric connections. Lift the system pressure solenoid shell slightly using a small screwdriver to access the catch. Unhook the cable. Pull out the cable and grommet from the gear case. Retain the holder.
16. Remove the valve body bolts (only bolts with 10 mm head). Retain the small cover.
17. Unhook the manual valve connecting rod from the valve control and remove the valve body.
18. Remove the two seals.
19. Remove the bolts securing the oil pump to the gear case.
20. Pull off the oil pump and brake unit B2 from the gear case using puller «87 92 699 PULLER (KM-993)»(ref-212247-S14696270032005122300000) .
21. Remove the brake hub and freewheel F1.
22. Turn the gearbox through 90° in the stand.
23. Remove the torque converter shell. Knock loose the housing with a plastic mallet. Remove the small seal.
24. Lift out the differential unit.
25. Remove the oil strainer and the cover plate.
26. Remove the oil channel plate from the gear case.
27. Remove the torsion spring and the ratchet spindle for the hand brake.
28. Remove the hand brake control rod and the gear position disc. Release the detent spring.
29. Remove the shaft seal for the selector lever shaft.
30. Remove the holder for the hand brake control rod and the detent spring.
31. Remove the hand brake ratchet and guide pin.
32. Remove the holder and torsion spring.
33. Remove the cover with O-rings, plunger and spring.
34. Lift out the output shaft assembly with thrust bearing and bearing races.
35. Lift out the C3 clutch and bearing race. Retain the thrust bearing.
36. Lift out the B4 brake bands from the gear case.
37. Remove the circlip for the freewheel F3 from the gear case. Lift out F3. Retain the small clip.
38. Remove the oil sealing rings by pressing one side of the ring towards the groove and unhooking the ring.
39. Turn the gearbox through 180 °
40. Remove the circlip, cover, plunger, spring and the two O-rings for the B4 brake plunger. Take care as the spring can thrust off the cover and plunger.
41. Remove the bolts securing the end cover. Knock loose the cover with a plastic mallet. Remove the four seals.
42. Remove the pipe for the C3 solenoid. Use sliding hammer «83 90 270 SLIDING HAMMER»(ref-212247-S29356398752005122300000) and hook «87 92 384 PULLER, TORQUE CONVERTER SEAL»(ref-212247-S39971217192005122300000) .
43. Remove the pipe holder and the second pipe. Use sliding hammer «83 90 270 SLIDING HAMMER»(ref-212247-S29356398752005122300000) and hook «87 92 384 PULLER, TORQUE CONVERTER SEAL»(ref-212247-S39971217192005122300000) .
44. Remove the bearing and bearing race from the cover and the bearing race from the turbine shaft assembly with clutches C1 and C2.
45. Lift out the turbine shaft unit with clutches C1 and C2. Retain the thrust bearing and thrust bearing race.
46. Lift out the planetary gear sun gear and thrust bearing. Retain the bearing race.
47. Remove the rear ring gear. Retain the thrust bearing and bearing race.
48. Lift out the planetary gear unit with the large thrust bearing.
49. Remove the circlip for freewheel F2 and brake B3 using a screwdriver. Lift out the ring gear with F2 and B3 that contain the clutch discs, disc plates and flange.
50. Retain the thrust bearing and bearing race.
51. Remove the circlip for the spring unit using a screwdriver. Lift out the spring unit.
52. If necessary, remove the accumulator for C1 from the end cover with spring and plunger.
53. Remove the plug from the end cover
54. Carefully apply an air pressure of 4 bar through the oil passage for B3 to remove the B3 plunger as illustrated. Use a pair of blunt nose pliers if the plunger will not come out.
55. Turn the gearbox through 90°.
56. Remove the circlip for the intermediate gear. Use circlip pliers «87 90 180 PLIERS»(ref-212247-S02549071322005122300000) with tips «87 90 297 JAW»(ref-212247-S06291195612005122300000) and a small screwdriver. Remove the intermediate gear.
57. Turn the gearbox through 90°
58. Remove the drive shaft seal using a hammer and screwdriver.
59. Fit puller «87 91 683 PULLER»(ref-212247-S39181019352005122300000) and «87 91 675 PULLER»(ref-212247-S05802703412005122300000) and remove the bearing race from the gear case by heating the case with a hot-air gun for about 5 minutes. Pull out the bearing race and retain the shim.
60. Remove the brake band holders and the remaining plugs in the gear case (do not get the plugs mixed up).
61. Remove the screw and pipe clamp from the torque converter shell.
62. Pull up both ends of the pipe with sliding hammer «83 90 270 SLIDING HAMMER»(ref-212247-S29356398752005122300000) and hook «87 92 384 PULLER, TORQUE CONVERTER SEAL»(ref-212247-S39971217192005122300000) . Remove the pipe. Take care not to damage the pipe.
63. Remove the oil channel plate (three bolts). Remove the three magnets.
64. Fit puller «87 91 675 PULLER»(ref-212247-S05802703412005122300000) and «87 91 683 PULLER»(ref-212247-S39181019352005122300000) . Heat the bearing seat for about 5 minutes with a hot-air gun and pull out the roller bearing.
65. Knock out the shaft seal.
66. Remove the bearing race for the taper roller bearing in the torque converter shell by heating around the bearing seat with a hot-air gun for about 5 minutes. Pull out the bearing using puller «87 91 683 PULLER»(ref-212247-S39181019352005122300000) and «87 91 675 PULLER»(ref-212247-S05802703412005122300000) . The bearing need only be removed when changing the torque converter shell or differential bearing.

Assembling the automatic transmission

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1. If changing the torque converter shell, transfer the outer plugs to the new shell. Carefully remove the old sealing compound from the sealing surface using a gasket scraper and wash the torque converter shell.
2. Heat the bearing seat using a hot-air gun and knock down the roller bearing into the torque converter shell using drift «87 90 461 SLEEVE, BEARING RING»(ref-212247-S17297853842005122300000) and shaft «83 90 189 DRIFT»(ref-212247-S23456585562005122300000) . Press in the bearing with the text face down until it bottoms in the torque converter shell. The side of the roller bearing will be the bearing race for the thrust bearing on the output shaft.
3. Heat the bearing seat for the differential bearing race in the torque converter shell. Fit the bearing race. Make sure the bearing race is all the way home.
4. Place the three cleaned magnets on the oil channel plate. Apply thread locking compound 74 96 268 to the bolts and fit the oil channel plate. Tightening torque 5.5 Nm (4 lbf ft)
5. Fit the pipe using a splinter-free plastic mallet. Take care not to bend or damage the pipe. Fit the pipe clamp.
6. Heat the bearing seat for the differential bearing race in the gear case for about 5 min. Refit the shim and fit the bearing race. Make sure the bearing race is all the way home.
7. Lubricate the bearings with automatic transmission fluid. Put in place the differential and fit the torque converter shell. Fit only every other bolt. Fit the dynamometer «87 92 483 TORQUE WRENCH»(ref-212247-S10115031942005122300000) and drift «87 91 337 DRIVER, MEASURING DIFFERENTIAL BEARING TORQUE»(ref-212247-S32824051652005122300000) into the differential housing. Turn until a stable value is obtained. Tightening torque 24 Nm (18 lbf ft) Measure the prestress. Start value: BEARING PRESTRESS VALUE SPECIFICATIONS New bearing 1.0 Nm (7 lbf ft) Refitted bearing 0.5 Nm (3.5 lbf ft)
8. If the prestress is not within specified limits, remove the differential and bearing race from the gear case and change shim. If the reading exceeds the specified value, change to a thinner shim. If the reading is lower than the specified value, change to a thicker shim. Shims are available between 1.0 - 1.90 mm in small intervals.
9. Remove the torque converter shell and lift out the differential.
10. Turn the gearbox through 90°.
11. Fit new O-rings on the B4 brake plunger and plunger cover. Lubricate with petroleum jelly and fit the servo plunger with cover. Fit the circlip.
12. Turn back the gear case 90°
13. Bend out the rings and fit them in their grooves. Do not bend more than necessary.
14. Lubricate the two oil sealing rings for clutch C3 with petroleum jelly.
15. Lubricate new O-rings with petroleum jelly and fit them on the accumulator plunger and cover. Fit the spring and plunger. Fit the cover and holder with torsion spring. Press down the holder and tighten the bolts. Tightening torque 10 Nm (7 lbf ft) IMPORTANT: Do not press the accumulator cap further down than the holder allows. The O-ring can be damaged on sharp internal edges.
16. Fit freewheel F3 into the bottom of the gear case and fit the small clip. (NB. Note its location)
17. Fit the circlip using a screwdriver. Make sure the circlip opening is not in line with any of the recesses in the groove.
18. Lubricate the O-ring for the hold-down bolt with petroleum jelly and tighten it. Tightening torque 140 Nm (104 lbf ft)
19. Lubricate the brake band with automatic transmission fluid. Fit the brake band with the pin of the hold-down bolt in the recess of the brake band.
20. Fit the thrust bearing lubricated with petroleum jelly. Place the black part towards the gear case.
21. Fit clutch C3 into the gear case while lifting the brake band slightly to facilitate fitting. Make sure the clutch rotates freely anticlockwise and is locked clockwise.
22. Align the teeth of the C3 clutch using a small screwdriver.
23. Fit the bearing race on the sun gear and the thrust bearing in the planetary gear. Fit the output shaft assembly into clutch unit C3. Make sure the shaft falls in place correctly in the recess for the large gear. Check that the shaft and gear rotate freely.
24. Fit the thrust bearing race and the thrust bearing on the output shaft unit.
25. Put in place the ratchet on the correct side of the spring.
26. Fit the guide pin into the hole and put in place the guide fork and the ratchet spindle and spring.
27. Fit the ratchet sector gear position spring. (Note the different bolt lengths.) Tightening torque 5.5 Nm (4 lbf ft)
28. Press a new oil seal lubricated with petroleum jelly into the selector lever shaft. Apply petroleum jelly to the lips of the oil seal.
29. Fit together the control rod and the ratchet sector and slacken the spring. Make sure the hand brake detent falls into position and is in working order. Put the selector lever in neutral.
30. Fit the oil control plate onto the gear case (short bolts). Tighten the bolts. Tightening torque 5.5 Nm (4 lbf ft)
31. Fit the cover with two bolts. Tightening torque 5.5 Nm (4 lbf ft)
32. Fit a new oil strainer and tighten the bolts. Make sure the seals are positioned correctly, one on each side. Tightening torque 5.5 Nm (4 lbf ft)
33. Fit the differential housing unit. IMPORTANT: Check the differential housing internally for damage. Also check the drive shaft surfaces.
34. Clean the sealing surfaces on the gear case and torque converter shell. Use cleaner 30 02 599. Keep the surfaces free from grease.
35. Fit a new seal in the gear case.
36. Apply a bead of flange sealant 87 81 841 approximately 1 mm wide to the gear case as illustrated and fit the torque converter shell.
37. Apply thread locking compound 74 96 284 to the internal bolts. Fit the bolts (different lengths). Tighten the bolts. Tightening torque 25 Nm (18 lbf ft)
38. Clean the magnetic surface on the drain plug and fit it with a new gasket. Tightening torque 40 Nm (30 lbf ft)
39. Put in place the intermediate gear assembly in the gear case.
40. Turn the gearbox 90°.
41. Use circlip pliers «87 90 180 PLIERS»(ref-212247-S02549071322005122300000) with tips «87 90 297 JAW»(ref-212247-S06291195612005122300000) and fit the circlip. Press the circlip into the groove with a pair of pliers.
42. Turn the gearbox 90°.
43. Apply petroleum jelly to two new O-rings for brake B3 and fit them on the brake plunger. Take care not to damage the O-rings. Press the plunger into the gear case.
44. Put in place the return spring unit on the plunger and fit the circlip in the groove on the gear case. Make sure the opening in the circlip is not aligned with the large recess. Use a screwdriver to make sure the entire circlip is in the groove.
45. Lay the bearing race and thrust bearing on the intermediate gear hub.
46. Fit the front ring gear and freewheel F3. Make sure the thrust bearing is positioned correctly and that the ring gear rotates freely anticlockwise and is locked clockwise.
47. Fit flanges, clutch discs and disc plates as illustrated. IMPORTANT: The large recess in the flanges and plates must be aligned in front of the brake bands to B4. Make sure that they are fitted in the correct order.
48. Fit the circlip into the gear case. Make sure the opening in the circlip is not in line with the recesses.
49. Apply an air pressure of 4 bar in the oil passage as illustrated. Make sure the plunger moves easily.
50. Lubricate the thrust bearing for the planetary gear with petroleum jelly and place the bearing on the front ring gear. Check that the black side is face up.
51. Fit the planetary gear.
52. Place the thrust bearing race on the planetary gear lubricated with petroleum jelly.
53. Lubricate the thrust bearing for the planetary ring gear with petroleum jelly and place the bearing on the front of the planetary ring gear. Lay the planetary ring gear on the planetary gear.
54. Lubricate the bearing race for the planetary gear ring with petroleum jelly. Fit the bearing race.
55. Lubricate the thrust bearing with petroleum jelly and fit the sun gear shaft.
56. Fit the planetary gear sun gear unit into the planetary gear.
57. Lubricate the thrust bearing for the planetary gear sun gear with petroleum jelly and place the bearing on the sun gear. Make sure the bearing is fitted correctly with the black side face up.
58. Centre the clutch discs and plates using a screwdriver. Fit ring gear and clutch C1 as a complete unit. Turn the intermediate gear and C1 towards each other so that the planetary gear engages in the ring gear.
59. Make sure the ring gear and clutch C1 have fallen in place by measuring as illustrated. The distance must be approximately 51 mm.
60. Fit the oil pipe. Use a splinter-free plastic mallet. Take care not to bend or destroy the pipe.
61. Place the clamp on the pipe and tighten the bolt. Tightening torque 5.5 Nm (4 lbf ft)
62. Fit the oil pipe for clutch C3 as illustrated. Use a splinter-free plastic mallet. Take care not to bend or damage the pipe.
63. Fit the bearing race for the rear cover. Lubricate the bearing race with petroleum jelly. Lay the bearing race and the thrust bearing in the C1/C2 unit.
64. Fit the accumulator for C1 into the end cover.
65. When changing the end cover, fit the oil sealing rings onto the needle bearing housing. Do not bend the rings more than necessary.
66. Fit a new sealing ring lubricated with petroleum jelly onto the shaft for C1/C2
67. Clean the sealing surfaces with cleaning fluid 30 02 599. Keep the sealing surfaces free from grease.
68. Apply a bead of flange sealant 87 81 841 approximately 1 mm thick on the rear cover.
69. Lubricate four new sealing rings for the oil holes with petroleum jelly and fit them on the gear case.
70. Fit the end cover on the gear case. Apply thread locking compound 74 96 284 to the bolts and tighten alternately. (Different lengths) Tightening torque M6 10 Nm (7 lbf ft) Tightening torque M8 25 Nm (18 lbf ft)
71. Turn the gearbox with turbine shaft 45° downward.
72. Apply petroleum jelly to the O-rings for the oil pump unit. Align the disc package with a small screwdriver. Fit thrust washers lubricated with petroleum jelly on brake B1/B2.
73. Fit freewheel F1 and the bearing race for brake B1 and B2 on the oil pump unit. Lubricate the bearing race for F1 with petroleum jelly and fit it.
74. Place the oil pump unit so its bolt holes are aligned with those in the gear case. Press the pump unit in place carefully. Tighten the bolts carefully and alternately. Tightening torque 25 Nm (19 lbf ft)
75. Turn back the gear case 45°
76. Make sure the turbine shaft has an axial clearance of 0.37- 0.9 mm. Use dial gauge «78 40 622 DIAL GAUGE»(ref-212247-S25456399732005122300000) and stand «87 90 727 BRACKET, DIAL GAUGE»(ref-212247-S00749435592005122300000) .
77. Fit the two sealing rings.
78. Connect the manual valve connecting rod to the manual valve control on the valve body unit. Screw in the bolts loosely. Take care not to fold the gasket.
79. Fit the gasket on the cover, fit the cover bolts. Tighten all the valve body bolts alternately. Tightening torque 10 Nm (7 lbf ft)
80. Apply petroleum jelly to a new O-ring and fit it together with the cable grommet and the wiring harness for the solenoids on the gear case.
81. Plug in the connectors to the four solenoids and secure the cables.
82. Clean inside the valve body cover. Remove any gasket remains from the contact surfaces on the cover and gear case. Clean the sealing surfaces with cleaning agent 30 02 599. Apply a bead of sealing compound 87 81 841 approximately 1 mm thick to the cover and fit the cover onto the gear case. Apply thread sealant 74 76 284 to the bolts (different lengths) and tighten the bolts alternately. Tightening torque 25 Nm (19 lbf ft)
83. Fit the oil temperature sensor in the gear case. Fit a new O-ring lubricated with petroleum jelly. Tightening torque 10 Nm (7 lbf ft)
84. Fit the oil temperature sensor cover plate with nut, washer and bolt. Tightening torque, bolt 25 Nm (19 lbf ft) Tightening torque, nut 10 Nm (7 lbf ft)
85. Clean the plate cover sealing surface and apply a 2 mm thick bead of sealing compound 87 81 841. Fit and tighten the bolts. Tightening torque 7.5 Nm (6 lbf ft)
86. Turn the gearbox 180 °
87. Fit new O-rings on the speed sensors. Clean the speed sensors and make sure there are no metal cuttings on the magnets. Apply petroleum jelly to the O-rings. Fit the two speed sensors in their correct positions. Note that on models where the cables are connected directly to the sensor, they are different lengths. Long cable = input shaft (A), short cable = output shaft (B). Plug in the connectors to the speed sensors and temperature sensor. Tighten the bolts. Tightening torque 5.5 Nm (4 lbf ft)
88. Fit the gear selector position sensor. Fit the holder for the cable grommet. Tighten the bolts on the gear selector position sensor first (important). Then tighten the nut on the gear selector position sensor and bend up the lock washer. Tightening torque 8 Nm (6 lbf ft)
89. Engage neutral and fit setting tool «87 92 467 ADJUSTMENT TOOL, GEAR SELECTOR POSITION SENSOR»(ref-212247-S23554512522005122300000) . Undo the bolts for the gear selector position sensor and adjust it so that the line is visible in the center of the groove in the setting tool. Tighten the bolts. Tightening torque 25 Nm (18 lbf ft)
90. Remove the setting tool.
91. Turn the gearbox through 90°.
92. Change the torque converter seal, see «ADJUSTMENT/REPLACEMENT»(ref-212247-S16062387522005122300000) «TORQUE CONVERTER SEAL»(ref-212247-S07350186752005122300000) .
93. Fit the torque converter. Use holder «87 91 766 GRIPPING TOOL, TORQUE CONVERTER»(ref-212247-S17527409822005122300000) . Fit locking device «87 92 574 HOLDER»(ref-212247-S03891516862005122300000) .
94. Make sure the torque converter has been fitted in the correct position and lay a steel rule on the mating face of the torque converter. Measure the distance between the mating face and the drive plate contact surface on the torque converter. The distance must be at least 15 mm.
95. Remove holder «87 92 681 HANDLE, TORQUE CONVERTER»(ref-212247-S22225485802005122300000) .
96. Fit new drive shaft seals. Use drift «83 90 122 DRIFT»(ref-212247-S39245805832005122300000)
97. Bind the wiring harness with cable ties.
98. Pry off the type plate from the changed case using a screwdriver.
99. Straighten the plate with a hammer. Widen the hole with a tapered drift and an M10 nut for support. Lay the plate on the new gear case and press it on. Use an M8 nut for support over the center pin and seal with a hammer.
100. Remove holder «87 92 392 HOLDER, TRANSMISSION»(ref-212247-S40767173122005122300000) form the gearbox.
101. Fit the «GEARBOX»(ref-212247-S04337975522005122300000) in the car. See fitting gearbox assembly. Remember to clean the oil cooler with flushing equipment «87 91 824 FLUSHING EQUIPMENT»(ref-212247-S26279213072005122300000) .

Scheme 244

1. Raise the car.
2. Place a receptacle under the car to collect fluid spill.
3. Undo the cover's retaining bolts and remove the cowling.

Scheme 245

1. Clean the sealing surfaces, removing all traces of adhesive and fluid.
2. Apply a thin coating of sealing compound, part number 87 81 841.
3. Fit the cowling in place. Tightening torque: 8 Nm (6 lbf ft)
4. Fill up with automatic transmission fluid to the correct level.

Scheme 246

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Scheme 253

1. Undo the circlip and remove the ring gear. Use gloves so as not to hurt your hands on the teeth.
2. If the bearings on the idler gear are to be changed, measure the rolling torque as illustrated and make a note of this. Use 83 90 130 Dynamometer and a piece of string.
3. Tap out the lugs from the lock nut.
4. Fix the shaft in a padded vice and remove the nut.
5. Press the output shaft out of the pinion using 87 92 210 Support, differential bearing in a hydraulic press. Hold the shaft so that it does not fall to the ground. Mark the bearing race with a felt-tip marker so it can be refitted in the same position.
6. Remove the retaining sleeve.
7. If necessary, tap the bearing races out of the idler gear using a hammer and drift.
8. Remove the inner conical roller bearing using 87 91 832 Puller, internal phi= 63 mm. Rotate the shaft a number of times while tightening the tool. Fit «87 91 642 BASIC TOOL»(ref-212247-S20187951152005122300000) and use an M10 nut as support. Clean all parts thoroughly.

Scheme 254

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1. Press bearing onto the pinion shaft. Lubricate with automatic transmission fluid. Use 87 91 204 Sleeve, bearing race.
2. Press in the bearing race on one side of the idler gear towards the inner circlip. Use 87 91 204 Sleeve, bearing race and the old bearing race in between. Press in the other bearing race in the same way.
3. Fit a new retaining sleeve.
4. Fit the idler gear. Lubricate the bearings with ATF.
5. Fit the conical bearing by carefully moving it towards the spacer ring. Use 87 91 204 Sleeve, bearing race.
6. Carefully press in the pinion with 87 91 204 Sleeve, bearing race.
7. Press the bearing race onto the output shaft. Fit the bearing in the same position as previously.
8. Turn several turns to allow the bearings to settle. Carefully tighten a new nut to the correct preload. Refer to the illustration. The preload for new bearings: 5.5- 13.5 N (1.2 - 3 lbf). Lock the nut. Preload for old bearings: See note made during removal.
9. Turn the planetary gear over and fit the ring gear. Squeeze the circlip and let the gear fall into place. IMPORTANT: Check that the circlip engages the groove in the idler gear.

For torque converter

Group: Automatic transmission

86 12 798 Toolboard T1 Service

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (HOLDER)

Scheme 263

Weight, fluid capacity and grade of fluid

FLUID SPECIFICATIONS

Tightening torques

TIGHTENING TORQUES SPECIFICATIONS

Scheme 264

Engine torque

The actual air mass/combustion is converted to torque, unit Nm. This information is sent continuously on a bus and TCM uses the information to control the system pressure.

Scheme 265