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SAAB
SaatlC11tUSA.lnc
SMbOnvt.PO BoAff7
O.lflOl.CT0&-477
8 /90
9005SPEED
900 5 Speed
Foreword
900 5 Speed
Transmission Identification
l.D. Tag
All transmissions carry an Identification tag on the top
of the primary housing. This plate shows the
transmission type and serial numbers. The type code
shown below for 1984 and later cars (see shop manual
for older models) allows you to match the transmission
to the appropriate parts listing ln the microfiche and
determine gear ratios and proper application without
having to open up the box.
'
772306
GM = Manual tmsmiS1lion
GA Au1omatic transmiS1llon
Transmission version
Manual
4
Number of teeth.
inpuVoulput gear
Anti-Theft Marking
Beginning with the 1987 model year all major components and body parts carry an anti-theft marking label.
Thi s label is the subject of a two page Service Information 08/86- 872, Section A-0, Page 21. Found In Supplement 6-A.
The central theme ofthis bulletin is that the labels must
not be removed or defaced In any way even when Installing the component In a vehicle with a different
V. J. N. number.
31/30
0.97
Gear ratio
SAAB 693n91
SAAB 693n91
6937791 SAAB
0.84
0.78
a
33/24
0.72
SAAB 6937791
6937791 SAAB
693n91 9'Wll
SPi."'8 6937791
SAAB 593ns1
SAAB 693n91
900 5 Speed
Specifications
Lubricants
Transmission Fluid - Engine oil 10W30or10W40,
3 U.S. qt.,
Alternate
Gear oil SAE EP 75 API GL4 or GL5
Saab part no. 99 00 754 (5 gallons)
Inner U joint grease - Saab ':J" grease
Saab part no. 02 70 025 (7 1/2 lb can).
Torques
Bearing Preloads
New Pinion Bearings
Used Pinion Brgs. (Over 1,200 Miles)
New Differential Bearings
Used Differential Brgs.
(Over 1,200 Miles)
18- 27 In lbs
7- 16 In lbs
16- 24 In lbs
. .. 8- 28
KGFCM
.. . 8- 3
KGFCM
7- 11 in lbs
900 5 Speed
Specifications
Sealants/Locking Fluid
Many of the bolts in the transmission are precoated
with thread sealant or locking fluid. The shop manual
draws your attention to these bolts with the picture
shown to the right. The accompanying bolt length chart
also highlights the coated bolts. Failure to recoat
these bolts with the proper compound when rebuilding
can result In leakage of gear oil or major mechanical
failures.
Locking Fluids
Loctite 270 (Red)
Pinion bearing nut
Lower chain sprocket nut
Forward pinion sllaft nut
900 5 Speed
Specifications
Sealants
1)
Permatex Aviation
900 5 Speed
Special Tools
-A
''' '
900 5 Speed
Special Tools
t. Q(\()ry!
Slide Hammer
87 90 917
83 90 270
Layshaft Puller
83 90 049
8790n6
Q.__<~-~~..:::'_>_O__..~._
-
.....
87 90 511
87 90 909
900 5 Speed
Special Tools
Spring Scale
83 90 130
Dial Indicator Holder
8790727
900 5 Speed
Special Tools
83 90 064
I:
; \
900 5 Speed
Special Tools
87 90 on
8790503
83 90 189
8790 685
78 41 075
8790800
10
900 5 Speed
Special Tools
11
900 5 Speed
Special Tools
12
900 5 Speed
Special Tools
--v
c:::::::::;:.~.:--
01r-----~
1990- Selector Shaft Lock
87 91 998
13
900 5 Speed
Gearbox Description
'14
900 5 Speed
Gaskets and Sealing Surfaces
....
GASKETS
The front, rear and side covers are sealed with gaskets.
No additional gasket compound is necessary.
METAL TO METAL
The joint between the malncase and primary hOuslng is
a metal to metal flt. Use of a gasket would alter Internal
clearances. The surfaces must #'e clean and
undamaged. Use Loctite 51
an anaerobic
compound, not blue goo.
s'.
BOLT THREADS
All bolts with holes drilled Into the transmission portion
of the case must be treated with Permatex Aviation
Gasket Compound (not needed on new pretreated
bolts).
15
900 5 Speed
Construction - Shafts and Gears
Matched Gears
Only the ring and pinion are a matched set, all others
may be replaced Individually.
16
'
900 5 Speed
Construction - Cluster Gear
Cluster Gear
Also known as countershaft or layshaft. The cluster
gear Is built up of two segments. The Input or fifth gear
portion Is joined to the main section by a splined
bushing locked In position with a snap ring.
Reverse Idler
The reverse Idler is In constant mesh with the cluster
and acts as a bridge between the cluster gear ai:!dreverse gear on the p inion shaft. These are the only
sliding mesh gears in the transmission and,
accordingly, the first to be damaged by abuse.
17
900 5 Speed
Power Flow
.
5
Reverse
Idler
18
'
~90~0~5~S~p=e=
e~
d ~~~~~~~~ ~
Power Flow
First Gear
Second Gear
19
900 5 Speed
Power Flow
Third Gear
'
Fourth Gear
Reverse
Idler
20
'
Power Flow
Fifth Gear
Reverse
Idler
Reverse
21
900 5 Speed
Synchronizer Construction
'
'
/I
,or/11() '\
v
Jf'
c~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
22
900 5 Speed
Synchronizer Operation
Neutral
The synohro sleeve Is centered on the hub. The synchro
ring Is In contact with its retaining ring but not with the
tapered face of the sleeve.
Neutral
Partially Engaged
The synchro sleeve has moved slightly to the right
towards the gear. The synchro ring Is In contact with the
sleeve, the friction created between these two
components starts to "synchronize" gear and pinion
shaft speed. The amount of friction Is dependent on
spring tension, oil viscosity and tempElfature, etc,
Partially
Engaged
Fully Engaged
Fully
Engaged
23
900 5 Speed
Selector Mechanism
Name
Function
A
B
i'
c
D
hi"-
cf/)le!"5 I J1-).r:J
24
'
900 5 Speed
Lubrication
Oil Specification
Only two basic types of olls are specified for this box,
engine oll 10W- 30 or 10W-40 and 75 weight GL 4 or
GL 5 gear oil. Never use a heavier oil such as a multi
weight gear oil, both shift quality and bearin91
lubrication will suffer, particularly in oold weather.
Oil Level
The primary housing has a series of oil collection
devices, not the least of wtlich is the chain tensioner.
Incidentally, It Is possible to install the tensioner upside
down with the oollectlng cup on the bottom wtllch
makes trapping oil rather dlffioult. When Installing a
rebuilt transmission preflll the primary housing with
approximately one pint of oil through the Input shaft
cover opening to Insure good lubrication and tensioner
action on start up.
25
900 5 Speed
Lubrication
Oil Level
Oil Flow
The bearings, bushings, chains, and gear surfaces are
lubricated by a combination of splash feed and gravity
flow through a series of collecting troughs and drilled
passages. This Is an effective, trouble free system. The
only common problem has been with technicians
failing to clean these passages during a rebuild and
recontaminating the gearbox.
26
900 5 Speed
Production History
Year
Identifying Characteristics
1980
Sand cast malncase. no mounting Cluster gear and third gear guide ring
bosses for the turbo exhaust pipe
modified during the model year to
bracket.
prevent loss of third gear synchro
spring.
1981
Die cast malncase with two mounting Snap ring on forward end of pinion
bosses tor the turbo exhaust p ipe
shaft must be Installed with sharp
bracket.
edges facing forward.
1982
Visually the same as 1981, check the New ring and pinion, 9:33
l.D. plate.
rather than 9:35 (3.89:1).
{3.67:1)
Large dipstick hole for combined oil Iii- Cast pinion bearing housing replaced
!er/dipstick (reducer bushing available
die- cast version, all die- cast housto install gearbox In older cars).
lngs should be scrapped.
Modified synchro cone angle, new
synchro sleeves.
Asymmetrical synchro sleeve teeth
on 2nd and 3rd gear.
New differential assembly with roll pin
locking the cross shaft in position.
27
900 5 Speed
Production History
Year
1985
Identifying Characteristics
Turbo models have a heavier Inner driv- Extended input shaft on turbo models
er with corresponding changes to
with support bearing In the front cover.
axles, bools and trunnion bearings.
The inner driver has two rather than Input shafts, bearing housing and
three external ribs.
spacers modified during the year to
reduce chain wear by offsetting the
lower sprocket.
Always verify that the transmission
has the correct inner drivers before installation.
1986 - 1988
Large Inner drivers phased In on non Gearboxes with new selector mechaturbo models as running change during
nism must not be interchanged with
1986. Also changes to the Internal sethe older style. If you mix and match
lector mechanism identified by a modiyou could have a car with two shift lelied rear cover and hole in selector shaft
ver centering mechanisms fighting
each other, or non at all.
for linkage adjustment tool. Modified
front cover for hydraulic front mount on
turbo.
1989
1990
28
900 5 Speed
Measuring
29
900 5 Speed
Teardown - Checking Backlash
2.
3.
Thickness
Part Number
0.10 mm
0.15 mm
0.30 mm
0.50mm
83
83
83
83
41 604
41 612
41 620
41 638
30
900 5 Speed
Teardown - Checking Pinion Depth
d~.Omm ~
DESIGN SPECIFICATION
31
900 5 Speed
Teardown - Checking Pinion Depth
'
The next ring and pinion produced might run best when
the pinion moves away from the ring gear center line by
0.05 mm. This means the measured distance has
increased to 60.05 mm and the pinion face will be
marked +5.
You can simulate this dial indicator reading by slowly
lifting the pinion depth gauge off it's base plate until the
pointer moves 5 graduations from O. Note that as you
increase distance the dial indicator moves counter
clockwise.
32
900 5 Speed
Teardown - Pinion Depth Checks
Tolerance
All settings have a tolerance of 0.05 mm.
For example, a + 8 pinion could read anywhere
between + 13 and + 3 and be within specification.
Pinion Shims
Thickness
-88
89-
0.10 mm
87 24 569
87 26 259
0. 15
87 24 577
87 26 267
0.30
87 24 585
87 26 275
0.50
87 24 593
87 26 283
33
900 5 Speed
Teardown - Pinion Depth Checks
34
900 5 Speed
Parts Inspection - Differential
Inner Drivers
Wash and Inspect the Inner drivers, wear will take place
where the axle trunnion bearing contacts the driver.
During the rebuild you should swap the drivers from
side to side. This will give the axle fresh contact points.
If there Is substantial wear the owner will complain of a
heavy vibration on acceleration as the axle drops Into
and cllmbs out of the wear pockets.
35
900 5 Speed
Reassembly - Differential Bearing Preload
Note:
1.
2.
36
900 5 Speed
Reassembly - Differential Bearing Preload
3.
Thickness
Part Number
0.10mm
83 41 604
0.15mm
83 41 612
0.30mm
83 41 620
0.50mm
83 41 638
37
900 5 Speed
Teardown - Pinion Bearings
Note:
38
900 5 Speed
Parts Inspecti on - Pinion Bearing s & Housing s
Pinion Bearings
llle heart of the transmission is the pinion bearing.
Unlike gears and synchros it Is false economy to reuse
pinion bearings (or any other bearing with more than a
few thousand miles of seNlce). If you have gone this far
put In new bearings, the latest pinion bearings for
80- 88 transmissions are of an Improved proflled"
design, Saab P/N 87 24 890. Don't just pull the
universal number off the old bearings and go to a
jobber, It will tit but It won't be right.
39
900 5 Speed
Parts Inspection - Pinion Bearings & Housings
..
40
900 5 Speed
Reassembly - Pinion Bearings
Press a new rear pinion bearing on the pinion shaft
using tool no. 87 90 636 and ring 87 80 925 (- 88) or 87
91 972 (89-).
Note:
41
900 5 Speed
Reassembly - Stack Height
42
900 5 Speed
Disassembly Inspection - Gears
Thrust Surfaces
All gears except reverse ride on bearings or bushings
and, In the case or the forward gears, have thrust
surfaces to control end float. Check the l.D. of the gear
for signs of wear or lack of lubrication and inspect both
end races for signs or damage to the thrust surfaces.
This Is partlcularty critical on 4th gear where the
stepped bushing will collapse If the 24mm pinion nut ls
overtorqued.
43
900 5 Speed
Disassembly Inspection - Synchromesh Sleeves
J c
.-
- .
-~ .
NEW
USABLE
Synchromesh Engagement Teeth
J c
These are the "gears" that grind when you miss a shift.
A certain amount of wear at this point is inevitable, it is a
waste of money to replace every gear or sleeve Where
someone has "kissed" the tip of the teeth.
..
: : ::-
SCRAP
44
'
..._
900 5 Speed
Disassembly Inspection - Synchro Rings
Note:
transmission.
45
900 5 Speed
Parts Identification - Gears
'
Tooth Count
There ar~ currently (spring of 90) three main families of
gears that you will encounter during repair work; -1980,
1981-88, 1989- . Many of these gears are similar
enough to one another so that is possible to put
together a box with the wrong parts. Always Check
tooth count, outer diameter, root diameter and spacing.
Important differences In the first two groups may be
found on S.I. 05/82-567 (section 4, page 71 of bound
S.I. Supplement No.3).
46
900 5 Speed
Parts Identification - Gears, Bearings
Synchro Teeth
In November of 1982 the tip angle of the synchro sleeve
engagement teeth on 2nd and 3rd gears was changed
to Improve cold shifting characteristics. The teeth on
1he later gears are asymmetrical. The earlier style gears
are no longer available.
Bearing Design
The support bearings at both ends of the cluster gear
were upgraded in 1982 production. In both cases the
bore In the gear for the bearing was Increased and the
bearing altered accordingly. The older gears have
been superseded by the newer style and the
appropriate bearing. Again these changes are noted
on S.I. 05/82-567. In 1989 production both bearings
were further upgraded by Increasing the roller count at
the from to 15 and,ln the rear, by installing a
combination inner race and thrust washer between the
layshaft and the cluster gear.
..' .
Symmetrical
Asymmetrical
47
::
900 5 Speed
Parts Inspection - Gulde Rings
Guide Rings
'
48
'
900 5 Speed
Parts Inspection - Synchro Springs
Gear
Color Code
Spring Tension
BLUE
10 N
87 11103
GREEN
30N
8715120
3&4
WHITE
24N
8700429
CLEAR
16 N
8715 005
Part Number
49
900 5 Speed
Parts Inspection - Synchro Rings, Hubs
Coated
Plain
1 &4
2&3
shown below.
Earl y
Late
87 20 419
l.D. for Late Cone Angle
50
9005Spee d
Parts Interchangeability - Gears & Synchro Rings
may be
Installed
In older
51
900 5 Speed
Parts Inspection - Shift Forks
"
'
II
I
Maximum 0.1 mm
52
900 5 Speed
Reassembly - Input Shaft Bearing Preload
2.
3.
4.
53
900 5 Speed
Reassembly - Input Shaft Bearing Preload
Reassembly - Input Shaft Bearing Preload
'
5.
Shim Thickness
Part Number
0.20 mm
8712 994
0.25mm
8713 448
0.30 mm
87 13 455
Part Number
7.28mm
8723 272
7.29mm
87 23 280
7.30mm
87 23 298
7.31 mm
87 23 306
Part Number
5.28mm
87 26 184
5.29 mm
87 26 192
5.30mm
87 26 200
5.31 mm
87 26 218
54
9005Speed
55
900 5 Speed
Reassembly - Ring and Pinion Backlash
the
backlash
and
compare
to
the
Specification
17 . .05 mm
56
900 5 Speed
Parts Inspection - Primary Chains
Minimum 1O mm
Minimum 10 mm
57
900 5 Speed
Shift Linkage Adjustment
l.
Adjust as follows:
1.
2.
3.
4.
58
900 5 Speed
Shift Linkage Adjustment
Mid 1986 Onward
At first glance the mechanism appears to be the same
but there are three Important differences:
1.
2.
3.
Adjust as follows:
1.
2.
3.
Lock the shift lever Into third gear with the 6mm
pin.
4.
59
900 5 Speed
Shift Linkage Adjustment
1980 - Mid 1986 Centering Mechanism
All 5 speed transmissions have a mechanism to
automatically center the shift lever in the 3 - 4th gear
slot. Up until mid 1986 this was accomplished by a pair
of spring loaded rollers mounted on the front of the
selector housing.
Adjust as follows:
1.
2.
3.
4.
5.
60
900 5 Speed
Slave Cylind er - Clutch Wear
The slave cylinder for the Saab 5 speed Is a unique
co-axial design with a "hollow" piston surrounding the
clutch shaft. It Is self adjusting, much like a disk brake
callper.
In principle all years function along the same lines but
there are some significant changes which affect the
following operations.
61
900 5 Speed
Slave Cylinder - Basic Setting
62