Driveshaft pinion "fell in" - what to do?! Saab 9-5 1.9 TID

[echazfraz]

Removed the gearbox to change clutch and flywheel.

During persuasion of gearbox from engine to ground I put my hand around the diff end and a finger into the n/s driveshaft hole.

In doing this I've managed to unseat the driveshaft pinion from its position and it has, for want of a better expression, fallen into the diff!

I can put my fingers in and move the pinion wheel around but can't manoeuvre it back into place.

Lifting the whole gearbox and turning it over etc. gets the pinion wheel moving around the diff but not into place.

I'm going to have to open the gearbox to move this back into place aren't I?! Balls.

[Richard-D]

I don't understand how this is possible. How could you ever insert the driveshaft if so?

Edited by Richard-D on Saturday 31st October 11:19

[imagineifyeswill]

Was the gearbox noisy before you removed it, this doesnt normaly happen unless the diff side bearings are well worn. You should be able to stick a pry bar in oneside and lift the diff assembly back up then put a spigot of some type in the other side to hold it in place.

[echazfraz]

Richard-D said:

I don't understand how this is possible. How could you ever insert the driveshaft if so?

Edited by Richard-D on Saturday 31st October 11:19

Me neither tbf - but it has. I have another gearbox now which I am going to use and in a spare moment I'll split the original and see wtf happened. I'll post pics!

[echazfraz]

imagineifyeswill said:

Was the gearbox noisy before you removed it, this doesnt normaly happen unless the diff side bearings are well worn. You should be able to stick a pry bar in oneside and lift the diff assembly back up then put a spigot of some type in the other side to hold it in place.

Something was very noisy, rumbly, possibly this? Tried lifting it up by poking various podgers into the hole but could not even get it square to then "reseat" from the other side.

I've another box now (there were other issues with mine - slave with rounded heads for one - and as above I will split my original in a spare moment and see what happened, then post pics.

Cheers for the advice anyway, I appreciate it.