Front Drive Axle: Adjustments Saab 9-7X I

Pinion Depth Adjustment

Tools Required

1. J 33838 Pinion Setting Gage. See «Special Tools»(ref-268154-S10977060352007101800000) .
2. J 29763 Static Timing Gage. See «Special Tools»(ref-268154-S10977060352007101800000) .

Scheme 73

Scheme 74

Scheme 75

Scheme 76

1. Lubricate the pinion bearings with axle lubricant. Refer to «Fluid and Lubricant Recommendations»(ref-268159-S32137604382007101800000) .
2. Install the J 33838-2 (1) and the bolt (2) to the outer pinion bearing.
3. Install the J 33838-2 (1) and the bolt (2) with the outer pinion bearing into the differential carrier assembly case half.
4. Install the inner pinion bearing onto the J 33838 as shown. See «Special Tools»(ref-268154-S10977060352007101800000) .
5. Install the J 33838 (2) with the inner pinion bearing into the differential carrier assembly and the bolt (1). See «Special Tools»(ref-268154-S10977060352007101800000) .
6. While holding the J 33838 stationary, install an inch-pound torque wrench on the bolt of the J 33838 and tighten the bolt. See «Special Tools»(ref-268154-S10977060352007101800000) . Tighten: Tighten the bolt until a rotating torque of 1.7-3.4 N.m (15-30 lb in) for new bearings or 1.0-2.3 N.m (10-20 lb in) for used bearings is obtained.
7. Rotate the assembly several times in both directions in order to seat the pinion bearings.
8. Check the rotating torque of the assembly. If the torque is less than 1.7 N.m (15 lb in) for new bearings or 1.0 N.m (10 lb in) for used bearings, continue to tighten the bolt until a rotating torque of 1.7-3.4 N.m (15-30 lb in) for new bearings or 1.0-2.3 N.m (10-20 lb in) for used bearings is obtained.
9. Place the contact pad of the J 33838 into the differential side bearing bore. See «Special Tools»(ref-268154-S10977060352007101800000) .
10. Install the J 29763 to the J 33838 by doing the following:. See «Special Tools»(ref-268154-S10977060352007101800000) . Install the collar and the lock nut onto the J 33838 . See «Special Tools»(ref-268154-S10977060352007101800000) . Do not tighten the lock nut at this time. Install the J 29763 into the collar. See «Special Tools»(ref-268154-S10977060352007101800000) . Place the stem of the J 29763 onto the contact surface of the J 33838 . See «Special Tools»(ref-268154-S10977060352007101800000) . With the stem of the J 29763 touching the contact surface of the J 33838 , push down on the J 29763 until the needle of the J 29763 has turned 3/4 of a turn clockwise. See «Special Tools»(ref-268154-S10977060352007101800000) . Tighten the lock nut of the J 29763 finger tight. See «Special Tools»(ref-268154-S10977060352007101800000) .
11. Rotate the J 33838 back and forth until the needle of the J 29763 indicates the lowest point in the differential side bearing bore. See «Special Tools»(ref-268154-S10977060352007101800000) .
12. At the lowest point of deflection, move the housing of the J 29763 until the needle indicates ZERO. See «Special Tools»(ref-268154-S10977060352007101800000) .
13. Move the J 33838 back and forth again to verify the ZERO setting. See «Special Tools»(ref-268154-S10977060352007101800000) . Adjust the housing of the J 29763 as necessary to set the needle to ZERO. See «Special Tools»(ref-268154-S10977060352007101800000) .
14. After the ZERO setting is obtained and verified, grasp the J 33838 by the flats and move the contact pad of the J 33838 out of the differential side bearing bore. See «Special Tools»(ref-268154-S10977060352007101800000) .
15. The value indicated on the J 29763 is the thickness of the shim needed in order to set the depth of the pinion. See «Special Tools»(ref-268154-S10977060352007101800000) .
16. Select the shim that indicates the proper thickness. Measure the shim with a micrometer in order to verify that the thickness is correct.
17. Remove the pinion depth setting tools.
18. Remove the pinion bearings from the pinion depth setting tools.
19. Assemble the differential carrier assembly. Refer to «Differential Carrier Assembly - Assemble»(ref-268154-S24364428382007101800000) .

Backlash Inspection and Adjustment

Tools Required

1. J 42213 Adjuster Sleeve Socket. See «Special Tools»(ref-268154-S10977060352007101800000) .
2. J 45224 Side Bearing Adjuster. See «Special Tools»(ref-268154-S10977060352007101800000) .
3. J 8001 Dial Indicator Set

Scheme 77

1. Remove all alignment marks made previously and re-mark the location of the differential adjuster nut sleeves in relation to the differential carrier assembly case halves. Ensure that the notches can be counted when turned.
2. Install the J 8001 (1-4) so that the button contacts the outer edge of the pinion yoke. Ensure that the button contact the outer edge of the pinion yoke and that the plunger is at a right angle to the pinion yoke.
3. Move the pinion yoke back and forth through the pinion yoke's free play while not allowing the ring gear to move.
4. Record the dial indicator reading.
5. To determine the actual backlash, divide the dial indicator reading by 2. An actual dial indicator reading of 0.16 mm (0.006 in) means that there is actually 0.08 mm (0.003 in) backlash. Specification: The backlash between the ring gear and the drive pinion should be between 0.08-0.25 mm (0.003-0.010 in) with a preferred specification of 0.13-0.18 mm (0.005-0.007 in). IMPORTANT: When adjusting the backlash, observe the following: Always turn the left and the right differential adjuster nut sleeves in equal amounts. Turning the differential adjuster nut sleeves one notch will change the backlash about 0.08 mm (0.003 in).
6. If the backlash is too small, increase the backlash by turning the right differential adjuster nut sleeve out one notch using the J 45224 , and the left differential adjuster nut sleeve in one notch using the J 42213 until the correct backlash is obtained. See «Special Tools»(ref-268154-S10977060352007101800000) .
7. If the backlash is too large, decrease the backlash by turning the left differential adjuster nut sleeve out one notch using the J 42213 , and the right differential adjuster nut sleeve in one notch using the J 45224 until the correct backlash is obtained. See «Special Tools»(ref-268154-S10977060352007101800000) .
8. Recheck the rotating torque of the pinion and differential assembly and adjust, if necessary. Refer to «Differential Carrier Assembly - Assemble»(ref-268154-S24364428382007101800000) .
9. Once the backlash and bearing preload is within specifications, remove the alignment markings and place new alignment marks between the differential bearing adjuster nut and the differential carrier assembly case.
10. Continue the assembly of the differential carrier. Refer to «Differential Carrier Assembly - Final Assembly»(ref-268154-S23684262252007101800000) .

Adjustments Affecting Tooth Contact

The following two adjustments affect the tooth contact pattern

1. Backlash adjustment
2. Pinion depth adjustment

The effects of bearing preloads are not readily apparent on hand-loaded tooth contact pattern tests. However, bearing preloads should be within specifications before proceeding with backlash and pinion depth adjustments.

Adjust the position of the pinion by increasing or decreasing the distance between the pinion head and the centerline of the ring gear. Decreasing the distance moves the pinion closer to the centerline of the ring gear. Increasing the distance moves the pinion farther away from the centerline of the ring gear.

Backlash Adjustment

Adjust the backlash by means of moving the side bearing adjuster sleeves which move the case and ring gear assembly closer to or farther from the pinion. Also use the adjuster sleeves in order to set the side bearing preload.

1. If the left side adjuster sleeve is moved in, along with an equal outward movement of the right side adjuster, the backlash will increase.
2. If the left side adjuster sleeve is moved out, along with an equal inward movement of the right side adjuster, the backlash will decrease.