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pchristy
V4 Guru

United Kingdom
1779 Posts

Posted - 21 Sep 2016 :  09:16:21 Show Profile Reply with Quote
Gareth, Set-up is fairly straight forward. Here's a list of Weber jet settings:



Mine is a DCD 23 (2nd one down), which I think most of them were, but it should be stamped on there somewhere. (Same as 1500 Cortina GT)

The only change needed to the jetting is a slightly richer idle jet in the primary choke. This is to compensate for the lower octane rating of unleaded fuel. Screw the mixture screw in until the engine falters, then back it out until its just running smoothly again - no need for a colourtune! It should end up between 1.5 and 2 turns open. If it isn't in this range, change the idle-jet until it is.

The idle jet controls the mixture until the barrel is about half open, so if you don't get this right, you'll get a stumble as the carb switches from one jet to another.

Other than that, all the suggested jet sizes seem to work just fine.

Best of luck, and let me know how you get on!

(Must get together sometime!)




--
Pete
"Duct tape is like the Force: It has a light side and a dark side, and it binds the Universe together!"
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Dirtbiker
V4 Mad

United Kingdom
720 Posts

Posted - 10 Oct 2016 :  21:17:18 Show Profile Visit Dirtbiker's Homepage Reply with Quote
Thanks Pete and let me know if you are heading to Plymouth, the kettle is always on!
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Dirtbiker
V4 Mad

United Kingdom
720 Posts

Posted - 17 Oct 2016 :  21:08:23 Show Profile Visit Dirtbiker's Homepage Reply with Quote
Not strictly SAAB related but got to drive this at the weekend!



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Betsy67
V4 Fanatic

United Kingdom
339 Posts

Posted - 18 Oct 2016 :  07:12:47 Show Profile Reply with Quote
Me too #128578; Not the same place though. Most enjoyable #128512;
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Dirtbiker
V4 Mad

United Kingdom
720 Posts

Posted - 16 Nov 2016 :  19:15:48 Show Profile Visit Dirtbiker's Homepage Reply with Quote
Hi All,

Not sure if you have seen my Gearbox troubles in technical but I will continue with progress here. If you haven't seen it basically my box is goosed!
I have made progress of sorts though. The first step was to dig out some likely candidates for replacement:



Excuse the grainy pic, just had battery power in the garage. Three potentials and Pete has sent me some useful links to help determine condition before fitting. One is a standout candidate, it's clean, it feels nice when put in gear and turned and the bloke I bought it off reckoned he wouldn't have kept it if it wasn't a good 'un. However it was very cheap and he couldn't remember for sure...

Working against this box is the drain plug:



Ouch! Moving on to box number 2 we have a hole in the top cover and it appears to be jammed in gear with no sign of any bits wanting to rotate - bottom of the list then!

Box number 3 is out of the very rusty 95 that drove to it's resting place many years ago. No reason why this wouldn't be a good one so we'll examine it more closely when time allows.

Also progress of sorts is that I have purchased one of these:



Not usually a fan of cheap Chinese tat but we'll see how it goes for occasional use.

Now all I need is some free time - I'll keep you posted!
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pchristy
V4 Guru

United Kingdom
1779 Posts

Posted - 17 Nov 2016 :  08:57:08 Show Profile Reply with Quote
Gareth,

If you can get that drain plug out, replace it with the one from the knackered box! (I know, obvious!)

I was always taught in school that warming the casing up would cause it to expand more than the plug, freeing it off. In practice, I found the opposite to be the case! You don't want drain plugs coming loose when the gearbox gets warm, so I assume they make them out of material that expands more than the casing!

We're meant to be in for a cold snap this week-end, so let it get *really* cold, then try and remove the plug. It might just work.....!

Best of luck!

P.S. That drain plug looks like it might be one of the later types, with a bar across the middle. My 95 originally had one of those. I made a special tool to remove it - a socket that was a good fit in the recess, and then cut some slots in the edges. It worked like a charm! I'll have a look and see if I still have it.....

--
Pete
"Duct tape is like the Force: It has a light side and a dark side, and it binds the Universe together!"

Edited by - pchristy on 17 Nov 2016 08:59:48
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Derek
V4 Guru

United Kingdom
1872 Posts

Posted - 17 Nov 2016 :  11:19:20 Show Profile Reply with Quote
A can of plumber's freezer spray might shrink the plug enough to loosen it. Heat the local area with a heat gun and then spray just the plug. Attack quickly! The modified socket is a good trick as long as you have one you're willing to take the grinder to.
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Dirtbiker
V4 Mad

United Kingdom
720 Posts

Posted - 17 Nov 2016 :  21:40:15 Show Profile Visit Dirtbiker's Homepage Reply with Quote
Thanks for the tips guys. I fear though the problem might be what to grip. Someone has already started to drill a hole in it presumably for an easy out attack...

Anyway, had a bit of garage time earlier and found another gearbox. I did think I was one short and a search in our outhouse revealed a gearbox plus some other bits and bobs I had forgotten existed. I now believe that the one from the outhouse is the one bought from a bloke who thought it was probably a good 'un. That means yesterday's favorite must have come from somewhere else - I think it came with a load of parts I bought locally a couple of years ago but no idea of it's history.

So, I have started working through some checks as advised on this link (thanks Pete):

http://www.vsaab.com/html/Articles/Trans_eval.htm

And I have come up with these results so far:

232720 Unknown origin but slim chance its the original box from the 96.
Selector cover off. Selector shaft seized but now freed off. Gearbox totally locked. Diff feels good. Release fork quite ovalised.

241760 Probably from local parts haul.
Lots of sideways play on input shaft.
Nice release fork. All seems good but locks when rotated backwards in gear. Maybe crown wheel damaged?

354035 from rusty 95.
Least sideways play out of all four on the input shaft.
Release fork a little ovalised. All feels good. Freewheel does engage but has a little drag. Selects forward gears well but wont select reverse.

344441 Probably from Weston Super Mare (good 'un - maybe)
Lots of play on input shaft.
No drive cups. Freewheel selector extremely stiff but engages and disengages.

That's as far as I got. What do the numbers mean? I'm guessing numerical order throughout manufacture which figures as the rusty 95 is a later car and this box has a higher number. I would be interested to try and figure out if I still have the original box from the 96 even if it's broken.

I hope this is interesting to someone but if not at least it's a good way of me recording what's what with all these gearboxes!

Cheers

Edited by - Dirtbiker on 17 Nov 2016 21:41:46
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melle
V4 Guru

United Kingdom
2831 Posts

Posted - 17 Nov 2016 :  22:44:17 Show Profile Visit melle's Homepage Reply with Quote
I've never seen a brass V4 gearbox plug before, all my boxes have steel plugs as far as I remember.

www.saabv4.com
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Andyinthegarage
V4 Fanatic

United Kingdom
357 Posts

Posted - 18 Nov 2016 :  18:31:28 Show Profile Reply with Quote
quote:
Originally posted by pchristy
Gareth, Set-up is fairly straight forward. Here's a list of Weber jet settings:






If this isn't already, can this highly useful reference be "Stuck" somewhere prominent and obvious?
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Dirtbiker
V4 Mad

United Kingdom
720 Posts

Posted - 08 Dec 2016 :  22:39:11 Show Profile Visit Dirtbiker's Homepage Reply with Quote
Minor update...
Not much progress but the dirtbiker household now has a new kitchen and I can almost see the diy tools being put away!
Got a couple of hours in the garage tonight and figured out why 354035 wouldn't go into reverse. There is a steel cap which allows the selector its full travel through the gearbox top cover and this was dented, probably because the box was removed with an International Harvester tractor...
Cap removed and massaged over a socket and now reverse is easily selected. This box is now "the chosen one", might swap the clutch release fork for a better one then aim to swap it over if we get a sunny day and I'm not at work...
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Dirtbiker
V4 Mad

United Kingdom
720 Posts

Posted - 27 Dec 2016 :  18:11:46 Show Profile Visit Dirtbiker's Homepage Reply with Quote
Hi All,
Good day on the 96 today, aimed for an early start and got going by 11:00, not a bad effort round here!
Engine and box out and "new" box attached along with a "new" clutch.
Engine and box back in with the driveshafts in place and now just need to connect everything up.
Here's some photos:







No photos of it back in as it was dark and cold! Having put the effort in building a garage it was nice to be working outside on the cobbled lane!

Cheers
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Andyinthegarage
V4 Fanatic

United Kingdom
357 Posts

Posted - 28 Dec 2016 :  12:10:05 Show Profile Reply with Quote
Good effort!

Can't have been easy moving the engine hoist around on cobbles!
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Derek
V4 Guru

United Kingdom
1872 Posts

Posted - 28 Dec 2016 :  12:26:17 Show Profile Reply with Quote
95 looks interesting. Brown so a rather late one. Have we been introduced?
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UK_Sub
Moderator

United Kingdom
2194 Posts

Posted - 28 Dec 2016 :  13:11:59 Show Profile Reply with Quote
That's what I was thinking Derek... looks like it has a fairly decent roof rack too!
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