SAAB WIS ONLINE

(475-2385 ed. 2) Drive shaft replacement

Symptom: Noise and vibrations from the drive shaft universal joints.

MODIFICATION INSTRUCTION
Bulletin Nbr: 475-2385 ed. 2
Date: ........... November 2003
Market: enl. separat lista
Drive shaft replacement

Customer Satisfaction Campaign 154 17

Cars in stock must be rectified before delivery.

A personal communication must be sent to the owners of cars already delivered requesting them to get in touch with the nearest Saab garage as soon as possible to have the fault rectified.

Cars affected

Saab 9-3 (9440) M03 within VIN range 31000001-31005124, equipped with automatic gearbox.

Background

The needle bearing holders in the drive shaft universal joint guide rollers are inadequately hardened which can result in the bearing holder breaking and the needle bearings falling out. This results in noise and vibrations.

Symptom description

Noise and vibrations from the drive shaft universal joints.



Parts required

12 786 414 Drive shaft (x 2)

90 223 979 Hub centre-nut (x 2)

90 542 019 Stuffing box

16-83 95 162 Protective collar

90 576 769 Nut (x 2)

16-87 81 684 Universal paste (sufficient for approx. 10 cars)

16-30 06 442 High pressure paste (sufficient for 10-20 cars)

40-12 799 118 Gearbox oil 3309 (delivered in packs of 12)

Procedure

Check box A2 on the modification identity plate before proceeding. Continue as follows if the box is not marked.

To remove




1. Raise the car and remove the front wheels.

2. Remove the hub centre-nuts.

3. Remove the steering swivel member screws, fold down the suspension arm and fit a 83 95 238 Wedge between the suspension arm and the anti-roll bar on both sides.


4. Undo the brake hose from the clip as well as the ABS cable holder on both sides. Turn the wheel for better access.

5. Press out the drive shaft approx. 10 mm from the wheel hub on both sides. Allow the drive shaft to remain in the wheel hub until the shaft has been removed from the gearbox and the intermediate shaft respectively. Use 89 96 951 Puller .

6. Left-hand side: Undo the steering servo pressure line's three clamps from the subframe. Draw the drive shaft out from the gearbox. Prise using 87 92 616 Removal tool, drive shafts . Lift away the drive shaft. Collect up the oil in a container.



7. Right-hand side: Knock the drive shaft out from the intermediate shaft using a brass drift and mallet. Lift away the drive shaft.



To fit




1. Left-hand side: Replace the shaft seal in the gearbox, see WIS - Transmission - Drive shafts - Adjustment/Replacement - Drive shaft, left-hand.

2. Fit the drive shaft in the wheel hub.

3. Left-hand side: Fit 83 95 162 Protective collar , drive shafts and fit the drive shaft in the gearbox. Lubricate the shaft splines with gearbox oil. Draw off the collar when approx. 20 mm remains. Press in the shaft until the lock ring snaps in. Fit the three steering servo pressure line clamps.

Right-hand side: Fit the drive shaft in the intermediate shaft splines. Lubricate the shaft splines using 87 81 684 Universal paste . Make sure that the seal to the intermediate shaft is fitted.



4. Remove the wedge and connect the ball joint to the steering swivel member. Fit the bolt and a new nut. Torque tighten the nut.

Tightening torque: 50 Nm (37 lbf ft)

5. Fit the brake hose in the clip and the ABS cable in the holder.

6. Fit the new hub centre-nuts loosely.

7. Fit the wheel. See WIS - Suspension, wheels - Wheels and tyres - Adjustment/Replacement - Wheels.

8. Lower the car and tighten the hub centre-nuts.

Tightening torque: 230 Nm (170 lbf ft)

9. Press the protective washer securely on the wheel.

10. Fill the gearbox with oil, see WIS - Transmission - Automatic Transmission - Adjustment/Replacement - Checking the oil level.


Marking the modification identity plate

Mark box A2 on the modification identity plate after completing this procedure. Mark with a "7" if the procedure was performed by the importer or "8" if performed by the dealer.

Time/Warranty information

See separate information.