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Home › Saab › 2005 › 9-2X Linear, 253, Standard › Repair and Diagnosis › Transmission › Manual Transmission And Differential › Main Shaft Assembly › Adjustment/Replacement › Assembly

Main Shaft Assembly: Adjustment/Replacement: Assembly

Assemble each sleeve & hub assembly.

NOTE: Position the open ends of spring 120° apart.
Fig 1: Positioning Sleeve And Hub Assembly
G03875332Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. 3rd-4th hub ASSY
  2. 3rd gear side
  3. 5th-Rev hub ASSY
  4. 5th gear side

Install the 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve & hub assembly for 3rd needle bearing on transmission main shaft.

NOTE: Align the groove in baulk ring with shifting insert.
Fig 2: Aligning Groove In Baulk Ring With Shifting Insert
G03875333Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. 3rd needle bearing
  2. 3rd drive gear
  3. Inner baulk ring
  4. Synchro cone
  5. Outer baulk ring
  6. Sleeve and hub ASSY

Install the 4th needle bearing race onto transmission main shaft using ST1, ST2 and a press.

NOTE: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST1 32005176 REMOVER 

ST2 32005159 RACE 4-5 INSTALLER 

Fig 3: Installing 4th Needle Bearing Race Onto Transmission Main Shaft
G03875334Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. 4th needle bearing race

Install the baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to transmission main shaft.

NOTE: Align the baulk ring and gear & hub assembly with key groove.
Fig 4: Aligning Baulk Ring And Hub Assembly With Key Groove
G03875335Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. Groove
  2. 4th gear side

Drive the ball bearing onto the rear section of transmission main shaft using ST1, ST2 and a press.

NOTE: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST1 32005176 REMOVER 

ST2 32005159 RACE 4-5 INSTALLER 

Fig 5: Installing Ball Bearing Onto Rear Section Of Transmission Main Shaft
G03875336Courtesy of SAAB-SCANIA OF AMERICA, INC.

Using the ST1 and ST2, install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft.

NOTE:
  • Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
  • Face the thrust washer in correct direction.

ST1 32005176 REMOVER 

ST2 32005159 RACE 4-5 INSTALLER 

Fig 6: Installing 5th Gear Thrust Washer And 5th Needle Bearing Race
G03875337Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. Face this surface to 5th gear side.

Install the bearing onto synchro cone.

Install the baulk ring and synchro cone onto 5th-Rev sleeve & hub assembly using ST and a press.

NOTE:
  • Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
  • Use a new ball bearing.
  • After press fitting, make sure the synchro cone rotates freely.

ST 32005147 INSTALLER 

Fig 7: Installing Baulk Ring And Synchro Cone Onto 5th-Rev Sleeve And Hub Assembly
G03875338Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. Baulk ring
  2. Synchro cone
  3. Ball bearing

Install the synchro cone stopper and snap ring to 5th-Rev sleeve & hub assembly.

Fig 8: Installing Synchro Cone Stopper And Snap Ring To 5th-Rev Sleeve And Hub Assembly
G03875339Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. Synchro cone stopper
  2. Snap ring

Install the rest parts to the rear section of transmission main shaft.

NOTE: Align the groove in baulk ring with shifting insert.
Fig 9: Aligning Groove In Baulk Ring With Shifting Insert
G03875340Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. Needle bearing
  2. 5th drive gear
  3. Baulk ring
  4. 5th-Rev sleeve & hub ASSY
  5. Lock washer
  6. Lock nuts

Tighten the lock nuts to the specified torque using ST1 and ST2.

NOTE: Secure the lock nuts in two places after tightening.

ST1 32005166 SOCKET WRENCH 

ST2 32005119 TRANSMISSION HOLDER 

Tightening torque: 

120 Nm (12.2 kgf-m, 88.5 ft-lb) 

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