Saab 2000-06

Overhaul

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900 And 9-3 Models



  1. Secure the driveshaft assembly in a vice
  2.  
  3. Remove or disconnect the following:

    Clamps and rubber boot
     
    Circlip
     

  4.  
  5. Tap the CV joint off the axle and take care not to damage splines
  6.  
  7. Rotate inner bearing to facilitate removal of steel balls and cage from outer race
  8.  

To install:

  1. Install or connect the following:

    New rubber boot onto shaft
     
    Inner bearing into outer race. Rotate so that steel balls can be inserted and pack with 80 grams Molycote Rapid G grease.
     
    Press joint assembly onto shaft
     
    Circlip
     
    Rubber boot retaining clamps
     

  2.  

9000 Models



  1. Secure the driveshaft assembly in a vice.
  2.  
  3. Remove or disconnect the following:

    Clamps and rubber boot
     
    Circlip
     

  4.  
  5. Tap the CV joint off the axle and take care not to damage splines
  6.  

To install:

  1. Install or connect the following:

    New rubber boot onto shaft
     
    CV joint and pack with 80 grams Esso HF Nebula EP2. 120 grams for Turbo model.
     
    Press joint assembly onto shaft
     
    Circlip
     
    Rubber boot retaining clamps
     

  2.  

Inner Joint



  1. Remove the driveshafts (1).
  2.  
  3. Clean, remove the circlip (2) and pull out the CV-joint tripod (3) from the shaft. Use a suitable 3-armed puller.
  4.  
  5. On models with B235R engines, bend out the plastic protector to remove the CV-joint from the housing.
  6.  
  7. Pull the rubber boot (4) from the driveshaft.
  8.  
  9. Wipe the CV-joint components and driveshaft clean.
  10.  

To install:

  1. Install the new rubber boot to the driveshaft and fit a new clamp.
  2.  
  3. Fit the CV-joint tripod. Make sure that its beveled edge is positioned inward on the shaft.
  4.  
  5. Install and tighten the circlip.
  6.  
  7. Fill the joint with new grease.
  8.  
  9. Join the driveshaft and CV-joint housing.
  10.  
  11. On models with B235R engines, bend back the plastic protector and make sure no protruding sharp edges can damage the rubber boot.
  12.  
  13. Thread on the rubber boot and fit a new clamp.
  14.  
  15. Install the driveshafts.
  16.  


    Click image to see an enlarged view

    Fig. Exploded view of the inner CV-joint assembly-9-3


9-5
Inner CV-Joints
  1. Clean the outside of the CV-joint assembly (1). Remove the boot clips (2). Remove the plate end (not shown) and lift off the CV-joint assembly (1).
  2.  


NOTE
The plate does not need to be refitted (only for production purposes).

  1. Wipe and remove the circlip (4) and pull the tripod (3) from the shaft. Use a suitable 3-arm puller.
  2.  
  3. Pull the rubber boot (5) from the driveshaft.
  4.  
  5. Clean the universal joint, tripod and driveshaft thoroughly.
  6.  

To install:

  1. Fit the new rubber boot (5) to the driveshaft and fit a new small clip.
  2.  
  3. Fit the tripod (3). Check that the chamfered edge on the tripod faces in towards the driveshaft.
  4.  
  5. Install a new circlip (4).
  6.  
  7. Pack the joint with new grease.
  8.  
  9. Join the driveshaft and CV-joint housing. Bend back the plate, if it has not been removed.
  10.  


NOTE
The plate does not need to be refitted (only for production purposes).

  1. Thread on the rubber boot and fit a new large clip.
  2.  


    Click image to see an enlarged view

    Fig. Exploded view of inner CV-joint assembly-9-5


  1. Clean the outside of the CV-joint assembly (1). Remove the boot clips (2). Remove the plate end (not shown) and lift off the CV-joint assembly (1).
  2.  


NOTE
The plate does not need to be refitted (only for production purposes).

  1. Wipe and remove the circlip (4) and pull the tripod (3) from the shaft. Use a suitable 3-arm puller.
  2.  
  3. Pull the rubber boot (5) from the driveshaft.
  4.  
  5. Clean the universal joint, tripod and driveshaft thoroughly.
  6.  

To install:

  1. Fit the new rubber boot (5) to the driveshaft and fit a new small clip.
  2.  
  3. Fit the tripod (3). Check that the chamfered edge on the tripod faces in towards the driveshaft.
  4.  
  5. Install a new circlip (4).
  6.  
  7. Pack the joint with new grease.
  8.  
  9. Join the driveshaft and CV-joint housing. Bend back the plate, if it has not been removed.
  10.  


NOTE
The plate does not need to be refitted (only for production purposes).

  1. Thread on the rubber boot and fit a new large clip.
  2.  


    Click image to see an enlarged view

    Fig. Exploded view of inner CV-joint assembly-9-5


Outer Joint




NOTE
This procedure applies to 9-5 models as well.

  1. Make sure the shaft and boot are clean. Fasten the drive shaft in a vice.
  2.  
  3. Loosen the clamps (2) on the outer CV-joint (1) and press the rubber boot (3) up the shaft. Clean the joint of any grease.
  4.  
  5. Expand the circlip (4) and tap off the CV-joint from the shaft with a hammer and a brass drift.
  6.  
  7. Turn the bearing so that the steel balls can be removed.
  8.  
  9. Turn the inner steel ball cage so that it can be removed from the outer cage.
  10.  
  11. Lift out the outer cage.
  12.  
  13. Clean all parts.
  14.  

To install:

  1. Fit a new rubber boot on shaft.
  2.  
  3. Place the outer cage in the CV-joint.
  4.  
  5. Place the inner cage in the outer cage and turn it so that the steel balls can be positioned.
  6.  
  7. Press in each ball.
  8.  
  9. Fill the CV-joint with new grease.
  10.  
  11. Press the driveshaft into the CV-joint.
  12.  
  13. Place the new rubber boot in the correct position and fit new clamps.
  14.  


    Click image to see an enlarged view

    Fig. Exploded view of outer CV-joint assembly-9-3 (except models with B235R engines) and 9-5



    Click image to see an enlarged view

    Fig. Exploded view of outer CV-joint assembly-9-3 (models with B235R engines)


 
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