Professional Documents
Culture Documents
Service Manual
SAAB
ront assembly
Steering device
M 1979-88-
632 Wishbones
641
642
+F
1l9if~
644
Units
The basic and derived units used throug hout the Service M?nua
l
are in accord ance with the 81 system .
For users not familia r with the SI units, some non-Co ntinen tal
units
are given in bracke ts after the respec tive SI unit.
The followi ng sY"!1bols and abbrev iatioll's are used:
.',
..
51 unit
mm
kg
N
Nm
bar
inch (in)
pound (Ib)
pound -force (Ibf)
pound -force foot (Ibfft)
pound -force per square inch (lbf/in 2 )
(Also abbrev iated: psi)
US liquid quart (liE! qt)
(Also abbrev iated: qts)
US gallon (USgal)
I (litre)
OF
Conversion factors
1 in = 25.4m m
1lbf= 4.45N
1/bfft = 1.36 Nm
1psi = 0.07 bar
1Iiqqt =0.95 1
1 US liq qt = 0.83 UKqt
1 mm = 0.039 in
1N = O.231b f
1 Nm = O. 741bff t
1 Dar = 14.5/b f/in 2
11=1. 05Iiqq t
1 USgal = 0.83 UKgal
Mali'lket codes
The codes refer to marke t specif ication s
AT
Austria
FR
France
AU
Austra lia
GB
Great Britain
BE
CA
Belgiu m
GR
Greece
Canada
IS
Iceland
CH
Switze rland
IT
Italy
DE
Germany
Denmark
JP
ME
Japan
DK
ES
Spain
NL
Middle East
Nether lands
EU
Europe
NO
Norway
FE
FI
Far East
SE
Sweden
Finland
US
USA
Saab-Scania AS 1988
Production: Technical Publications. Saab-Scania. Trollhattan.
Sweden
Te~hnical
data 02_6-1
Toe-in.
Camber
\<l-----A----'>t
1<r--....g--B----e>I
S 4351
Castor
Manual steering
degrees (0)
10.5
Power-assisted steering
degrees (0)
20.5
degrees (0)
2 0.25
Manual steering
degrees (0)
0.5 0.5
Power-assisted steering
degrees (0)
O.5 0.5
degrees (0)
O.25 0.25
Camber
mm(in)
2 1 (0.08 0.04)
Power-assisted steering
mm (in)
2 1 (0.08 0.04)
mm (in)
degrees (0)
11.5 1
Outer wheel
degrees (0)
20
Inner wheel
degrees (0)
20.750.50
Saab900
mm(in)
2(0.08)
Radial play
rnm(in)
1 (0.04)
Molycote Longterm 2E
Ball-joint lubricant
1mm
t>
<!
1mm
t>
?
55-70
40-55Nm
en
N
-g
en
~-10-95Nm
75-90 Nm
Saab900
steering system
Shim thicknesses
mm(in)
Nm (Ibfft)
Tightening torques:
Yoke cover plate bolts
Nm (Ibfft)
16 - 20 (12 - 15)
Fixing bolts
Nm (Ibfft)
60 - 80 (44 - 59)
Nm (Ibfft)
nonadjustable
Track-rod end locknut
totrackarm
--
Nm (Ibfft)
45 - 50 (33 - 37)
110 -130 (81- 96)
Nm (Ibfft)
60 - 80 (44 - 59)
Nm (Ibfft)
50-60(37-44)
Tightening torques
45-50 Nm /110-130 Nm
25-28 Nm
II
,
I
I
II
I
I
II
mm (in)
Tightening torques:
Pinch-bolt in UJ
Nm (Ibfft)
25 - 34 (18.5 - 25.1)
Nm (Ibfft)
25 - 28 (18.5 - 20.7)
i ;.
I
. "
Saab 900
.;
3.6
Dampi ngyoke
"
Servo fluid
cl(liqq t)
Lubric ant fordam peryok e, pinion
and rack
Rack-a nd-pin ion geartig htenin g
torque , car raised
..
'
Fixing bolts
Nm (Ibfft)
Nm (Ibfft)
20 - 34 (14.8 - 25.2)
Pinion locknu t
Nm (Ibfft)
30 - 45 (22 - 33)
Damperyol<e locknu t
Nm (Ibfft)
60 - 90 (44.4 - 66.6)
Nm (Ibfft)
Nm (Ibfft)
60 - 80 (44 - 59)
Nm (Ibfft)
50-60 (37-4 4)
to track arm
t--60 -80N m
......."b... _
~80.100Nm
'~
~
r
. 0-0 iG9-~til
N~r~ .
'
. ~,-_.n
t~
5060
~~
~e J
6080N m ~
~ct:.30-45
. Nm
'.
Y''@.-
~. 1'
~
0
~
~> 7~
~O'80 Nm
Minimu m
After adjust ment
Newbe lt
----..
I:,
N (Ibf)
N (Ibf)
N( Ibf)
Saab900
,.
220 (49.5)
290 - 330 (65.3 - 74.3)
400 - 490 (90 - 110)
5060 \\1m
i,
G;
....
~
("')
(f)
~
~
Track-rod ends
mm(in)
2 (0.08)
Radial play
mm (in)
1 (0.04)
Axial play
mm (in)
2(0.08)
Radial play
mm(in)
1(0.04)
Permanently lubricated
Molycote Longterm 2E
Manual system
mm (in)
100 (3.94)
Power-assisted system
mm (in)
125 (4.92)
mm (in)
2 (0.079)
Saab 900
.'. ,,-.~
CG?4
/ ,.
[
PiC
",
. i
Saab 900
89964 72
"c"
S 1\20
Saab900
c
8390148 Removal sleeve for control valve
(special tool for section 4)
2
(
co
~
<.0
(f)
8393209 Insert
Saab900
Front-wheel suspension
Steering swivel member
Wishbones
.
Steering column assembly
Manual steering system .
600-1
600-1
600-3
600-3
600-4
~~~r-r---1
:..,....:;,..:r:--"..--.---2
Track-rod ends . . . . . . . .
Power-assisted steering system
Servo pump . . .
Wheel geometry. . . . . . . '.'
600- 4
600- 5
600- 8
600-11
<0
.~
<J)
Coil spring
Rubber bump stop
Bottom spring seat
Anti-roll bar
Damper
Lower wishbone
.. '
ee n
g swve me beH'
Saab900
"
Saab 900
t-
1
2
3
4
5
6
7
Hub centre-nut
Washer
Hub
Outboard drive shaft and CV-joint assembly
Bearing with seals
Brake disc
Inboard drive shaft
1
2
3
4
5
Upper wishbone
Lower wishbone
Rubber bush
Bearing bracket
Shims
1
2
3
4
Saab900
Saab900
inside the cylinder acts on the rack, thus providing power assistance to t/1e rack-and-pinion
gear. The mechanical corriponents of the rackand-pinion gear are lubricated by a high-viscosity grease and sealed from the hydraUlic circuit
and other parts of the system by means of seals
and rubber gaiters.
illl
2 Servo pump
3 Control valve
4 Servo cylinder
-c
.1
3 Control valve
4 Servo cylinder
Cont&"O~ vaRve
(2), a torsion rod (3) and the pinion (4). The intermediate shaft is splined to the valve and one end
of the torsion rod is secured to the splined joint
by means of a pin (5).
The other end of the torsion rod is press-fitted in
the pinion, to which the spool is secured by
me"ans: ofa pi n (6), with the resu It that the spool
foiiows the rotation of the pinion exactly. There is
also' an additional splined joint between the
vqlve and the pinion as a fail-safe measure. The
top ofthe pinion is supported in a needle bearing
and the bottom in a ball bearing.
1 Valve
2 Spool
3 Torsion rod
4 Pinion
5 Pin
6 Pin
7 Radial grooves
Saab 900
600- 6 Technical
descrip~ion
1,
3I 4
;
.'.,
~.. ,'
1
2
3
4
5
6
..' ~;ift!.~EM:~~~~
.. .J",-~.k~tr~r~~~
~c::===============================================::!J
Control valve and servo cylinde r
When the steering wheel is turned, the movement is transferred via the torsion rod to the pinion. Because the torsion rod twists slightly, there
will be i:l difference between the degree of rotation ofthe valve (which follows the rotation of the
intermediate shaft) and the spool, which is fixed
to the pinion.
The f.luid can no longer flow through the control
valve back to the reservoir but instead flows
through the flow and return passages for the
servo cylinder: For a right turn. the fluid is
';' pumped to the right side of the servo cyl inder via
the top radial groove (C) in the spool. Atthe same
time, fluid is discharged from the leftsid e of the
. servo cylinder via the bottom radial groove (0) in
the spool. The fluid flows up through the valve
into the chamber above the spool and is returned
to the reservoir (8). For turning left, the opposite
circuit is opened.
Saab900
Technical'description 600-7
Steering straight ahead
Turning right
1
:2
1
:2
._~t
'I
.:'t~~
>'ll!,
'}I,l"
Racl<
Piston
Pressure-equalizing capillary tube
Inner ball joint
Track rod
Track-rod end
SelfVo cyDornco'leuo
The cylinder is part ofthe rack housing. The rack
(1) is equipped with a piston (2) complete with
se,als, For flow between the cylinder and the control valve there are two pipes, connected one on
either side ofthe piston. Forturning right, fluid is
pumped to the right side of the cylinder, forcing
the piston and rack towards the left, whereupon
fluid is discharged from the left section of the
servo cylinder. Simultaneously, the gaiter on the
LH side is distended and that on the right comr
Saab900
"
Both pumps incorporate a control valve for regulation of the pressure and flow.
flfi'illi1cill1l~e lQl~
operation
': 4'
Saab900
4....
\-
..... '.
,,'
..
1 Connecti ng passage
2 Spring
3 Reliefvalve
A = From delivery side of pump
B = To rack-and-pinion gear
C = To intake side of the pump
Saab900
"
".
Saab 900
"
~-----,--A----01'>i
...
,;-,:.
The toe-in value must always be positive, i.e. dimension B must be greater than dimension A.
B - A = Positive value
Toe-in
CambeR'
Camber refers to the angle formed between the
wheel and the vertical. If the wheel tilts outwards, the camber angle is said to be positive; if
it tilts inwards, the angle is said to be negative.
The camber on the Saab 900 is positive.
:.'
..,'" .::
~".:
... ":, ..
:. I
::
: "
::".:
'.
",
Camber
Castoii'
Castor is the angle at which the swivel pin (king
pin) deviates from the vertical when viewed from
the side. When the swivel axis is inclined backwards as shown, the castor is said to be positive;
when inclined fOlvlJards, the castor is said to be
negative. The Saab 900 has positive castor.
Castor
Saab900
':."
.~. .
~.:
"'~'
'~. -
"
. :..:':.:.,01
I
. . ."
",,'
'l"
~.
'"
(/)
SteerrDl1lg aDilg~es
The ideal steering angle for perfect rolling of the
wheels on cornering varies with the speed ofthe
car and the tightne ss of the turn, owing to suspension movement and deflection ofthe tyres on
cornering.
-- -
",
. " , ~'!
Because the track arms are turned slightl y inwards in relation to the path taken by the car, the
angle of the inner wheel on cornering will be
slightly greater than that of the outer wheel.
N
'"
-g.
(/)
f
!
601-1
601-1
601-2
601-3
601-3
Swivel-pin inclination . . . . .
Checking the steering angles
Reference tabl~ for adjusting
camber and castor
601-4
601-4
601-6
I<>----A------e;
5 To prevent distorted readings being obtained, rock the car firmly a few times to
allow the suspension to settle before starting any checks.
For checking of wheel alignment and steering
angles, the car must be unladen, with nobody inside it, but with a full tank of fuel and on a perfectly level surface. Adjustment by means of
shims must only be attempted within reasonable
limits; shims must not be used to correct major
discrepancies.
2 Using the tracking gauge, measure dimension A between the rims, at axle height.
Mark the measuring points with chalk. Roll
the car forward until the chall, marks are at
axel height again and then measure dimension B.
In this method, the tracking gauge remains
in the same position on the floor for both
measurements, thereby preventing any unevenness in the surface of the floor from influencing the measurements.
3 If adjustment is necessary, dothis by adjusting the length of the track rod. Slacken the
locknut at the track-rod end and the cl ip securing the gaiter on the steering rack.
4 Gripping the track rod with a suitable tool,
turn it clockwise or anticlockwise the
number of turns shown in the table on page
601-2 until the correct toe-in is obtained.
Make sure that the gaiter does not turn with
the track rod.
Saab900
Tracking gauge
3 SI ide the rubber gaitert oward s the rack-andpinion housin gto expose the groove in which
itseals .
4 Measure dimension C.
Dimension C, the distance between the
locknu t and the edge of the groove for the
gaiter, must never be allowed to exceed
100 mm (3.94 in) on cars with manual steering, or 125 mm (4.92 in) on cars with powerassisted steering.
Measured
toe setting
C
C
E
E
.....::l
(j)
t-
E
E
"
C
(j)
t-
6
5.5
5
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
5.5
6
6.5
7
7.5
S
8.5
9
9.5
10
Sports
chassis
1.6 out
1.5 out
1.5 out
l.4ou t
1.4 out
1.30u t
1.30u t
1.20u t
1.2 out
1.10u t
1.10u t
1.00u t
1.0 out
0.9 out
0.90u t
O.Sout
O.Sout
0.7 out
0.7 out
0.6 out
0.6 out
0.5 out
0.5 out
0.4 out
0.4 out
0.30u t
0.3 out
0.2 out
0.2 out
O.lou t
O.lou t
Correct value
Correct va Iue O.lin
O.lin
0.2in
0.2in
0.3in
0.3in
004 in
004 in
0.5in
0.5in
0.6in
0.6in
0.7in
0.7in
O.Sin
O.Sin
0.9in
0.9in
1.0 in
1.0 in
1.lin
1.lin
1.2 in
1.2in
1.3in
1.3in
104 in
1.4in
1.5 in
1.5 in
1.6in
1.6in
1.7in
\.
I'
)
(
,'-.
','
;:
S 4351
Camber
N.B.
The wishbone bearing nearer the back of the car
is available in a thinner variant which allows a
wider adjustment range. See the Parts
Catalogue.
iT'
i '
1
i~
I~
I
I
I
I
I,
. ....
:"'
Ir
::
I,
: ~ >-, "
Saab 900
Castor
: ':;'
'.
:."; ~.
,";.
.:"," .. :
:.
'.-
..:\.
"
Altering of the camber will also alter the swivelpin inclination by the same amount. Because the
ba'sic swivel-pin inclination is determined by the
design of the steering swivel member, it cannot
be adjusted.
If the swivel-pin inclination is wrong after the
camber has been set correctly, the fault must lie
with the steering swivel member, which must
therefore be replaced.
,,'
'.! ': .( .: .
"
" I.:
Swivel-pin inclination
\'
Jr----' .
r" ,
\\
, \\ \
\
\
\,
".
,\
,'.
\\ \"',
.\'
""0
','
:'.:: 2'0'
.
::
."
,:,'
-'.:
r--
LO
N
\6'
(/)
'.
Steering angles
Saab900
Outer wheel: 20
Inner wheel:
20. 75
0.5'
Saab900
Ca
belr/cals
mba
(0)1/' <dl
llJJS
2 From the box at which the two values coincide in the table we get:
F+ 5
B+3
which tells us that the front (F) wishbone
bearin g bracket requires 5 mm additional
(+) shimm ing and the back (B) bearin g bracket an additional (+) 3 mm.
1 Assume that the followi ng values are obtained when checking the front wheels on a
car with manual steering:
camber
castor
-1/4
1 3/4
F+3
R+7.5
F+3
R,7
1 1/2
F+Z
R+6.'
1 1/4
114
1/2
3/4
1 1/4
1 J 12
I 3/4
2 1/4
2 1/2
F +3,'
R+6,5
F +4
R+6:5
F +4,5
R+6
F +5
R+G
F+6
R+6
F +6.'
R+5,5
F +7
R+5,)
F+7
R+5
F +7.5
R+5
F+8
R+ll.5
F+8
R+4
F+Z
R+6
F +Z.5
R .. 5,'
F+3
R+5,5
F +3,'
R+)
F+4
R+5
F+5
R+5
F+5,5
R+4.5
F +6
R+4
F+6
R+3.5
F ,6,5
R+3.5
F+7
R+3
F+7
R+Z.'
F +l
R+5
F+l,5
R+,
F +1,5
R~4,5
F+Z
R+4,5
F +Z.5
R+4
F +3
R+4
F+4
R+4
F +4,'
R+3.5
F +5
R+3
F+5
R+Z.5
F +5.'
R+Z.5
F +"r,
R+Z
F+6
Rd.5
F -0,5
R+4
F':O
R+4
F +0,5
R+3
F +.1
R+3
F+l
R+Z.5
F~].5
R+Z.'
F+Z
R+Z
F,3
R+Z
F +3.5
R+2
F+4
R+l,5
F +4.5
R+I.'
F ,4.5
R+l
F+5
R+O,'
3/4
F -1,5
R+3
F -1
R+Z.5
F -J
R+Z
F -0,5
R+Z
F':O
R+I.'
F +0,'
R+I.'
F +]
R+I
F +],'
R+l
F+2
R+O"
F +2,5
R+O"
F+J
R':O
F +3.'
R-0,5
F+4
R-l
liZ
F:" -3
R+Z"
F-3
R+Z
F -Z,5
R+I.,
F -Z
R+l
F-l
R+O"
F-O,'
R+O"
Carr.
value
F +0,5
R-O,'
F +1
R-O"
F.Z
R-l
F +Z"
R-I"
F+3
R-Z
F+J
R-Z"
F -4
R+l
F-3"
R+O.5
F -3
R':O
F -Z.'
R-O"
F -Z
R-O,'
F-l"
R-I
F -I
R-l
F-O,'
R-1.5
F.!.O
R-l,5
F +0"
R-Z
F +J
R-Z
F+I
R-2.'
F +1"
R-J
F -5
R-O"
F-4"
R-l
F -4"
R-l,5
F-4
R-J.'
F-3.5
R-Z
F -3
R-Z
F-Z
R-Z
F-l.'
R-Z.'
F -1
R-Z"
F -1
R-J
F -0"
R-3
F.!.O
R-4
F .. 0,5
R-4
F-6
R-l"
F-6
R-Z
F -5,5
R-Z"
F-,
R-Z"
F -5
R-3
F -4"
R-J,5
F -4
R-4
F -3
R-4
F-Z,5
R-4
F -Z
R-4"
F -1.5
R-4.'
F -1.,
R-'
F -1
R-5
F -7
R-2,5
F-7
R-3
F -6,'
R-3,5
F-6
R-3,5
F-6
R-4
F-5,5
R-4,5
F-'
R-'
1-4
R-5
F-3,5
R-,
F -3
R-5,5
F-Z.5
R-5.5
F-Z
R-6
F -Z
R-6.5
F-8
R-4
F-8
R-4,5
F -7,'
R-5
F -7
R-5
F -7
R-,,5
F -6,5
R-',5
F-G
R-G
F-,
R-6
F -4,5
R-G
F -4
R-6,5
F-3.5
R-6:5
F-3
R-7
F-3
R-7.'
1/2
J/4
1 1/4
1 liz
1 3/4
2 J/4
2 liZ
Z 3/4
3 1/4
3 liZ
'aD
Q)
"0
....Q)
.0
ro
J 14
-1/4
-liZ
-3/4
Saab900
631-1
631-2
For any ball-joint play to be detected, the wishbones must be relieved of the tension imposed
by the coil spring and damper.
1 Fit insert83 93 209 underthetop wishbone.
,/
;t
4 Inspect the rubber seals for damage and replace any that are defective.
Saab900
. .
631-3
Wishbones 632'-1
.~
~'
Upper wishbone
632-1
Lower wishbone . . . . . .
To remove
N.B.
Before the upper wishbone on the left-hand side
can be removed, the engine will first have to be
removed. See section 2, subsection 201, of the
Manual
1 Wishbone
2 Bearing bracket
3 Bush
4 Shims
Saab900
632-12
632- 4 Wishbones
Cars not fitted with hydraulic engine mountings:
o
Saab900
Wishbones 632-5
o
,.
Saab900
632-6 Wishbones
Thoroughly clean all parts before refitting and replace any that are worn or damaged.
1 Fit the rubber bushes: apply soapy water to
the bushes and press them into the bearing
bracl<ets using tool 7841331.
N.B.
Oil or grease must not be allowed to come into
contact with the rubber bushes. Use only soapy
water.
/
Tightening ~orque:
55 70 Nm (40:7 - 51.8Ibfft)
00
N.B.
Direction of travel
-:;.--:"--:;...";..-'
---_..
---..------
Asymmetric wishbone
Saab 900
Wishbones 632-7
3 Position the wishbone complete with bearings ready for fixing to the body.
~.f~ >~.j . ~ ~
III
Saab900
632-8 Wishbones
o
Screw on the three nuts at the top, leaving them slack. Refit the bump stop
(where applicable).
((
~\
Saab900
Wishbones 632-9
o
Saab900
632- 10 Wishbones
7 Fit, and tighten the bolt securi ng the spring
seat (1) to the wishbo ne and the two bolts
(2) for the ball joint.
i i
,'I
Saab900
Wishbones 632-11
9 Remove the spring compressor with jaws.
'~
Saab900
632..:12 Wishbones
is bo e
If the: wishbones have been subjected to violen t
stresses as a result of a collisio n orthe like, they
must be carefully inspected for signs offailu re or
distortion. If found to be defective in any way,
they must be replaced.
1 Wishbone
2 Bearing brac!<et
3 Bush
10 D'ell1love
1 Raise and support the car and remove the
road wheel.
2 Undo the two bolts (1) securing the
wishbone to the ball joint. If an anti-roll bar
is fitted, move it out ofthe way.
,
Saab 900
Wishbones 632-13
r-
.;
Thoroughly clean all parts before refitting and replace any that are worn or damaged.
N.B.
Oil or grease must not be allowed to come into
contact with the rubber bushes. Use only soapy
water.
.; ..'::7841349
:-'
.
Tightening torque:
7590 Nm (55.5 66.6Ibfft)
"
",.
Tool 7841349
/\ 1] )
,,:C/o'
'"
_ ', .
00
Saab900
632-14 Wishbones
2 Raise the wishbone.
3 Tighten the six fixing bolts.
Saab900
Steering wheel . . . . .
Steering column assembly
641- 1
641- 4
Caution
Never hammer or use any form of impact
tool to remove or refit the steering wheel.
To remove
1 Remove the steering-wheel padding:
On three-spoke wheels, unhook the rubber
flanges on the padding from the spokes.
I.
I'
.,"
Saab 900
.. 641-11
3 Using two screwdrivers, prise off the actuator for the cancelling mechanism forthe direction indicators. (N/A to M79 or M80 cars.)
Saab 900
l~;'_~--------
,,",:-
,~ .....
!.
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TigMen!rreg torque:
25 - 28 Nm (18.520.7 ibf ft)
Saab900
"W~~.~D~
"/
Saab900
,/
El
To dismant~e
1 Remove the circular contact.
Saab900
'. ...
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Saab900
i.
~,
loassembfte
1 Press in the top needle bearing.
2 Slide the steering-column shaft into position from below as far as it will go.
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Saab900
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I
Saab900
II .
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1.
>'
t e gll'i]
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slna
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1 Remove the gaiter by levering the bush towards the intermediate shaft and then cutting away the gaiter.
Early variants of tool 89 95813 can be modified for use on 900 models by increasing
the width of the slot to 32 mm.
8995813
Saab 900
$7094
Saab900
Removal . .
Refitting . .
Dismantling
Assembly ..
642-2
642-3
642-4
642-6
642-11
642-11
7
~ '\~
;.,
(6
")
hi)"
~
24
& 12
~~
15~ 16 18
23
21
14 17
/~
20
t.- ;
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--1
22
23
24 .
lU!llililuII
19
Rack-and-pinion gear
1
2
3
4
5
6
'7
8
i.
13
9
10
11
12
Rack housing
Rack
Pinion shaft complete with bearing
Seal
Gasket
Cover plate
Needle bearing
Damping yoke
Spring
Gasket
Shims
Cover plate
iI; ::
)---_-->-
1l
jJr:)
0-10
11--0
'idE...
j"
~8
9~
Saab900
5 Separate the universal joint on the steeringcolumn shaft from the pinion shaft, move
the rack assembly to the side and withdraw it
through the aperture in the engine-bayfloor.
1\1.18.
Take care to avoid damaging the gaiters against
sharp edges.
Saab900
2 Reconnect the universal joint on the intermediate shaft to the pinion shaft. Ensure
that the pinch-bolt is located in the groove in
the pinion shaft.
Pinch-bolt tightening torque:
25 - 34 I\\m (18.5 - 25.2 ibf ft)
(
I
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I
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Tightening torque:
50 60 Nm (37.0 - 44.4lbf ft)
5 Check the toe-in and steering-wheel position and adjust as necessary (see subsection 601). Tighten the locknuts on the track
rods.
lightening torque:
60 - 80 Nm (44.4 59.2IbHt)
Saab 900
r.
Caution
The collaps ible steerin g column must be
handle d with care. If it is knocked or
treated roughly the preset length of the
telesc opic section can be altered and the
energy-absorbing proper ties ofthe column
impaired.
When filting the steerin g column, make
doubly certain that the spline d joint is slid
fully home on the pinion shaft, so that the
groove in the shaft lines up with the pinchbolt. The joint should slide easily onto the
shaft; should the spline s bind, never tap or
hamm er the top of the column .
Sim i larty, never hamm er or use any form of
impac t tool to remove or refit the steerin g
wheel.
When the front wheels are off the ground,
never forcibl y swivel a front wheel, causing
the steerin g to spin to full lock. This can
very easily result in seriou s damage to the
steelilng system. Operating the rack-andpinion gear by swivel ling a road wheel will
cause the steerin g wheel to spin at high
torque, exerting a powerful torsional
stress on the steerin g column when the rotation is arrested by the stop in the rackand-pi nion gear.
1\ .. '
. "."
."
iii
Saab900
Cautioll1
Under no circumstances must force be
applied to the pinion when undoing or
tightening the ball joint.
(jl
-(
Saab9011
6 Undo the bolts securing the pinion and remove the pinion complete with bearing,
cover plate and seal.
The bearing is factory-fitted on the pinion
shaft and cannot be replaced separately.
Only complete bearing and pinion shaft
units are available.
Saab 900
I
i
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.,....
- f
Tightening torque:
4550 Nm (33.337.0 Ibfft.)
Ball-joint preload:
7.332.0 N (1.7 5.4Ibf)
Cautio6'B
The maximum preload value of 32.0 N
must not be exceeded in any direction of
the track rod. If the amount of preload cannot be brought within the specified range
by adjustment, the track rod and ball caps
must be replaced.
,f
Saab 900
. ,.
':::~;'" ~
8 Refit the damper yoke, spring, sllims, gasket and cover plate.
...
10 With the rack-and-pinion gear correctly adjusted, the torque loading on the pinion
should be 0.8 -1.7 Nm (0.59 -1.26Ibfft). To
check this, measure the moment of force required to rotate the pinion by means of a
spring balance, 18-mm bihexagon socket
and a suitable socket handle. Ifthe length of
the handle (lever) is approx. 15 em, the reading on the spring balance should be between
5 and 11 N (1.15 - 2.53Ibf).
Saab900
Cal!JltfiorD
Under no circumstances must force be
applied to the pinion when undoin g or
tighten ing the ball joint.
o
.....
o
co
d:,,;g"l&,,~ Cf.l
. -",
l {
Tighten the ball joint to the specifi ed torque using 'C' spanner 89964 72 and a
torque wrench.
Tighte ning torque :
1.10 - .130 Nm (81.4 - 96.2 Ibf ft)
:i~1:i~~;{~::" '..
~. ~
N.B.
The rack must be removed from the vice before
the flupse t.
S 6 003
Saab900
i\
?r.
ADI"HUIS
UlI1g
gear.
There are two types of adjustment that may be
necessary:
A Adjusting the radial play in the rack
B Adjusting the inner ball joints on the track
rods.
For adjustment of the inner ball joints, the steering gear must be removed from the car. However,
it is easier to adjust the radial play in the rack
with the steering gear fitted, unless the steering
gear is removed for some other reason. As very
little wear takes place in the inner ball joints,
these will seldom need adjusting. For details of
how to make the adjustments, refer to the section on how to assemble the rack-and-pinion
gear (page 642-6 et seq.).
Saab 900
Rep~tdlcnfi1lgtmck=ll'@(D]
643-1
ell'\lds
rod using the same number of turns as reqUired to remove the old one and leave the
locknut slack,
Saab 900
..
643-2
i'~
i(
Saab900
Removal
Refitting
Dismantling
644-2
644-6
644-9
644-15
644-23
Assembly ..
Servo pump.
3a "2
4b
,4a
~.'5:. .,. .1..3 .
6 ~
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16 1.8
..
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.'
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..
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8
9
10
11
12
13
14
15
16
Seal retainer
"0" ring
Circlip
Needle bearing and race
Ball bearing
Locknut - ",
End cap
Dust cap
Damper yoke
Saab900
17
18
19
20
21
22
23
24
25
Spring
Adjusting screw
Thrust washer (end stop)
Inner ball joint and track rod assembly
Rubber gaiter
TraclHod end
RHO variant
Shim (on reassembly)
Rubber bush
<s,:>< \~t}J
\~
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(--
I\
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..-
...
Saab900
Saab 900
,,Jr
'.':
{-
,<'
12 Turn the rack-and-pinion gear assembly towards the front, so that the pinion shaft
points downwards, and then move the assembly as far as itwill go tothe right (looking
towards the front of the car).
Saab900
,.
'.. h
1 Move the rack to the LH end of its travel (pinion end), hold the assembly with the pinion
shaft pointing downwards and lift the assembly into position.
Saab900
,.',r",
9 Check the condition of the "a" ring on the return pipe and then reconnectthe return pipe
to the pinion housing (16-mm spanner).
Saab900
Saab900
. .
. ' ~:~~\".""';'~~":':I
).
N.B.
Under no circumstances hold the pinion when
undoing or tightening the ball joint.
Saab 900
..
'
,.
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M
~.
(I)
Remove the rubber cap from the narrowbore hole in the end of the rack housing
and push in the end of the circl ip by
means of a sawn-off electrical screwdriver (3 x 15 mm). Bend baek and withdraw the eircl ip using a hook made from a
piece of 1-mm piano wire (see drawing).
Saab 900
9 Lift out the damper yoke. If it proves obstinate, tap the housing gently on the workbench.
10 Tap off the end cap on the bottom of the pinion housing.
I:
I
Saab900
Saab900
..
(:
housing.
To assemble
1
permost.
3 Tap in t e lower pinion bearing sing a suitable socket {e.g. 19 'TIm} as a dri .
N.B.
Two piston variants are in use: one fitted wi h
piston ring 8937070 alone; and the other wih
both a piston ring (8970873) and an "0" ring
(8970865).
As from date code 6A 052 on the steering gear,
the piston must be fitted with both a piston ring
{89 70873) and an "O"ring (8970865). The
date code is stamped on the damping yoke adjus ing screw; the first digit denotes the year of
manufacture. and the last three digits the day of
manufacture.
Pis ans requiring both a piston ring a d an
"O"ring also carry a groove adjacent to 'he
groove for the piston (ing.
Neither the piston rings nor the "0' ring are Interchangeable.
8 Fit a new "0" ring onto the outer seal retainer. Inspect the seal itself; if it is in good
condition it can be refitted. If a new seal is
required, use tool 8996407 to fit it.
ssmra
,~
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9 Fit the bush (1) on the rack, with the narrower end inwards.
10 Slide the wave spring washer (2) up to the
bush and then fit the hydraulic seal (3). Take
care not to damage the sealing lip.
Saab900
l~
,"
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~~~.
. ....
~
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51110
of
.~;~~.;
..
S 1109
".
~~J. ~~...:,,#~
"
Tightening torque:
30 . 45 Nm (22.2 - 33.3IbHt)
!I
I
i
'l
II
I
"t,
Saab900
40 and 60.
Gl
Ti~hten
the locknut.
Tightening torque:
6090 Nm (44.4 6G.6Ib ift)
Saab900
I
I
I
r.
N.B.
Under no circumstances hqld the pinion when
undoing or tightening the ball joint.
.1
..
t: .,
Saab900
'
N.B.
To enable the circlip to be removed again in the
future, one end of the circlip must be directly in
line with the hole in the rack housing.
o
11ghienlng torque :
80 -100 \\1m (59.2 74.0 Ibfft)
5aaib900
..
.1
To remove
1 Drain the fluid from the system as follows:
e Undo the fixings forthe fluid reservoir and
I'J
Saab900
Saab900
.~
..
To refit
'I:'
'
I:
,.:t.
4 Loosely fit the pump bracket nut, the top fixing bolt and the adjusting screw. Ensure that
the bracket is in position on the bottom fixing bolt.
Saab 900
..
'"
Saab900
I
1
j
I.
Yo wemove
1 Drain the fluid from the system as follows:
o Disconnect the return hose from the
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i,
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Saab900
Saab900
r(
To remove
1 Drain the fluid from the steering system as
detailed in the first three paragraphs of step
1 on page 644-2. Disconnect the discharge
pipe.
(.
2 Disconnect the negative (-) battery lead and
cover the terminal pole on the battery. Undo
the fixings for the alternator and move it out
of the way.
I,
~~d-6
-+,;;.!.--2
11"---1
Saab900
~~~~6
--+-.,.;;<--2
Saab 900
c.
lRemoval/re~fittililg<of
......
. r)/
~.'
.'~
pump shaft
.'
"
/,
:)
(l'
"
.-
.' $aall900
Caution
Never apply any force to the pump shaft
during removal/refitting of the pulley.
1 Press in the end cover and prise the retaining ring out of the groove by inserting a
screwdriver through the hole in the pump
casing.
i. ( '
Saab 900
"
~~~;L"""
Saab900
10 assemble
1 Fit the "0" ring.
f:!
rn
"'
2 Fit the pin inside the casing and insert the
spring.
SaabSOO
Saab900
1 Unscrew the fitting from the reservoir casin~( Lift out the control-valve plunger and
spring.
Remove the pump from the casing by tapping lightly on the nut and bolt.
Saab 900
..
r .
Saab900
.1
12 Remove the "0" ring from inside the pump
casing.
iro assemble
1 Fit the "0" ring inside the pump casing.
Saab 900
,.~.
. ........
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en
"'co.
Ol
Saab900
8 Lubricate the "0" ringan d press on the reservoir casing using sleeve 87 91311 (special
tool for section 4,900 0 gearbox).
Press carefully to avoid damaging the edge
of the casing.
__________
Saab 900
_ _ _ III
Saab900
Saab Automobile AS
Trollhattan, Sweden
..