These are a few of the buggered up transmission parts that I found in the bottom of a transmission I just rebuilt for a customer. This was strange because I usually don't find this sort of damage. It was also strange because the transmission was CLEAN inside. Clearly, someone had been into it recently and had screwed up the job. Also--parts were missing and every case bolt was WAY too tight, as if it had been put together using an impact wrench, which is NOT a good idea. ALL the bolts/nuts in these Saab transaxles must be torqued to the specs provided by Saab in their factory service manual.
Once I had the bell housing off, it was clear what had happened. The nut at the end of the countershaft [shown] had come loose. The shaft then "floated" and the result was that every part shown--3 gears, the shaft, low and second synchronizer rings, the synchronizer hub and a bunch of smaller parts--were all busted up and had to be replaced. All because the moron who was into the transmission last did not correctly torque the nut at the end of the countershaft. OY!
Well, here is the reassembled gearbox. All countershaft-related damaged parts--as well as others damaged because of the countershaft problem--have been replaced. Note that the 'box is in my factory transmission jig. Using this jig--and the 20-odd factory tools that go with it--is the ONLY way to be sure that an overhaul of one of these transaxles is done correctly.
There are a number of internal adjustments that MUST be done correctly--some with correct thickness shims, some with feeler gauges, and this one with a dial indicator set up--to insure long life and reliability of the transaxle.
Here is the finished transaxle. I always specify the use of synthetic transmission oil--AMSOIL being the BEST, in my opinion--so I use an anerobic sealer, which is not attacked by synthetic oils--for all case mating surfaces, and on both sides of the rear cover and top cover gaskets.
Another view of the completed transaxle. Note that there is NO freewheel control lever. This unit has been "neutered" so the freewheel--a carry-over from two-stroke engine days--does not function. It is very easy for the V4 engine--which actualy has TORQUE [compared to the two stroke] to damage the freewheel unit. It is worth noting that I DO NOT weld internal parts to neuter the freewheel! At any time in the future, the freewheel system COULD--if the owner got soft in the head--be put back into use.
City Car Design
6 years ago