Saab 95 1967, Service Manual

Page: 400 / 610

Countershaft with bearings and gears
20. Place the countershaft
21. Reassemble the 1st and 2nd
and the synchronizer unit
22. Lift this assembly into the
the countershaft, complete with the lst speed gear
needle bearing, through the rear end of the trans-
mission case at the same time.
As from transmission No. 108911, the Ist and 2nd
speed gears are splines mounted.
NOTE
If the rear bearing, bearing seat and reverse gear have
not been removed, they may remain on the shaft
during reassembly. In this case, however, the bearing
must first be pressed into the seat and the rear retain-
ing ring removed from the shaft.
with its rings.
transmission case, passing
23.
Place the spacer on the shaft between the 2nd speed
gear and the front ball bearing. Then pass the shaft
through the front bearing and into the counter shaft
gear wheel.
24. Drive the countershaft in with the pass screw and
tool 78 41 091. In so doing, make sure that the
shaft splines engage with the synchronizer hub and
that the shaft passes into the countershaft gear.
Use the peg wrench 78 41 240, to turn the shaft.
Refit the retaining ring for the rear bearing after
pressing home.
DRIVING IN COUNTER SHAFT
Tools 78 41 000, 78 41 091, 78 41 240 and 78 61 347
471—8
NOTE
[f the countershaft is refitted complete with reverse
gear and bearing, use tool 78 41 091. This tool is al-
so to be used if the reverse gear and the seat with the
bearing are mounted separately.
25. Engage two gears simultaneously, e.g. 2nd and 4th,
and turn the 3rd speed gear in order to align the
key grooves in the counter shaft and the counter
shaft wheel. Drive the key in with an arbor.
26. Refit the friction wheel together with a new fric-
tion washer and star washer. Tighten the counter
shaft end nut with a torque of 80 Nm (60 ft.lb.,
8 kpm). The primary shaft and pinion shaft nuts,
the latter left hand threaded, should also be tight-
ened with a torque wrench at this stage.
Tighten the pinion shaft nut initially with a toque
of 120 Nm (90 ft.lb., 12 kpm), back off, and re-
tighten with a torque of 60 Nm (45 ft.lb., 6 kpm).
The primary shaft nut is to be tightened with a ter.
que of 50 Nm (35 ft.lb., S kpm).
NOTE
Check that the friction wheel is not located outside
the opposing gear and that there is sufficient clear-
ance between the primary shaft ball bearing and the
counter shaft gear. See "Friction brake".
27.
Secure the nuts on the main- and pinion shaft. The
main shaft lock washer tab is bent over the nut.
The pinion shaft nut is locked as follows:
a. Use the press screw as dolly against the front end
of the pinion shaft so that a small clearance is ob-
tained between the flange ring on the rear pinion
bearing and the gear box cover. Thereby preven-
ting damage to the bearing when the nut is up-
set.
b. Upset the nut collar in the three recesses in the
lock washer with a rounded drift.
If the pinion adjustment is not already correct,
leave the pinion shaft nut unlocked until adjust-
ment is carried out.
Fobr 1977