SAAB WIS ONLINE

Complete automatic transmission

Complete automatic transmission

To remove


1. Place drapes over the wings to keep the paintwork clean and protect it from damage.

2. Remove the upper engine cover and the battery cover.


3. Disconnect the battery terminals and remove the battery. Undo the cable clamp under the battery tray.


4. D223L: Remove the cover with vacuum tank, etc., and bend aside the cover. Press in the catch, detach the power steering fluid reservoir with bracket and move aside.

5. Unplug the bonnet switch connector.

6. Remove the battery tray.


7. Disconnect the ground cable from the engine bracket and the reversing light switch connection.


8. Detach the gear cables from the transmission by pulling the locking sleeves back. Lift up the cables from the levers. Carefully move them aside.

9. Fit 30 07 739 Hose pinch-off pliers to the clutch hose and undo the quick-release coupling from the clutch slave cylinder.

10. Remove the upper gearbox bolts. D223L: The bolt for the starter motor is longer than the other two.


11. D223L: Place 83 94 850 Lifting beam on the engine. Take the weight off the engine and gearbox.


12. B207: Fit 83 96 178 Lifting eyes B207 to the engine and 83 94 850 Lifting beam with 83 95 287 Holder


13. Undo the upper bumper shell mountings.

14. Suspend two 83 95 212 Strap in place above the radiator core so they are accessible from below.


15. Raise the car.

16. Remove the front wheels.

17. Remove the lower engine cover (D223L), and the front spoiler shield. Detach the hose to the headlamp washers and unplug and remove the connector. CV: Remove Chassis reinforcement, front subframe, CV


18. Secure the radiator core with the straps.

19. Remove the radiator brackets from the subframe.


20. Remove the front part of the exhaust pipe by cutting the pipe 87 mm from the front end of the silencer. Use 83 95 667 Pipe cutter/exhaust system .


21. Remove the bolt and nut holding the suspension arm to the steering swivel member on both sides.


22. Detach the anti-roll bar from the link arm.

23. Unplug the connector and detach the cable clip of the headlamp angle sensor (option)

24. Remove the engine torque rod from the subframe.


25. Remove the steering gear from the subframe.

26. Put the nuts and washers in a safe place. Let the steering gear hand in place.

27. Remove the clamps holding the power steering pipe from the subframe.


28. Remove the front part of the wing liner and bend it out of the way.


29. Place 83 95 311 Trolley lift and 83 94 801 Parent fixture underneath. Position the guide pins and adjust the height with spacers to keep it level.


30. Remove the subframe bolts and the rear brackets.

31. Lower the subframe slightly.

32. Remove the anti-roll bar from the subframe, protect the steering gear boot. Fit bolts loosely in the link arms so the anti-roll bar is kept hanging in place.

33. Pull out the steering arm ball joints from the steering swivel members.

34. Lower the subframe.

35. Remove the torque rod bracket. Undo the bolt for the torque rod for easier fitting.


36. Place a receptacle under the car, remove the level plug and the drain plug. Drain the gearbox oil. Refit the oil plug.

Tightening torque 45 Nm (33 lbf ft)

37. D223L: Remove the bolts in the coolant pipe bracket and move aside.


38. Remove the bolts in the charge air pipe bracket and move away the pipe.


39. Remove the lower transmission bolts. Leave one bolt in place loose.

40. Disconnect the ground lead.

41. Detach the ABS cable from the clip using a screwdriver and undo the left-hand drive shaft using 87 92 616 Removal tool, drive shafts .


42. Suspend the shaft by means of a cable tie.

43. Lower the car, mark the positions of the bolts on the left-hand engine bracket with a marker pen for correct refitting and then remove the bolts from the mounting.


44. Lower the power train about 70 mm with the lifting beam to facilitate removal of the gearbox.

45. Raise the car, move aside the power steering cooling coil and suspend it with a 83 95 212 Strap .


46. Fit 87 92 608 Holder for single-column lift onto a column jack. Adjust and secure the tool in the transmission as illustrated. Use bolt of 8.8 grade that are about 20 mm longer than the bolts that were removed.

47. Remove the last bolt, pull out the transmission and lower it.

Important

The jack can tip over. Be careful.


48. 51. Lift the transmission down from the column jack with an engine lift and 87 92 442 Lifting cable while undoing the lifting tool from the transmission.

49. Plug the holes for the drive shafts if the transmission is to undergo transport.


To fit


1. Bleed the slave cylinder if necessary.

2. Lubricate the primary shaft splines, see Summary of lubricants and sealants .

3. Lubricate the guide sleeves on the engine with anti-corrosion agent.

4. Fit 83 95 162 Protective collar, drive shafts in the right shaft seal in the transmission. This is done to protect the seal while the transmission is being fitted. Lubricate the seal.

Important

Always replace the shaft seals in the gearbox. Lubricate with gearbox oil.



5. Fit the gearbox with the lifting tool on the column jack.

Important

Slide in the gearbox until approx. 20 mm are remaining and remove the tool 83 95 162.


6. Push in the rest of the gearbox. Turn the crankshaft if necessary to get the gearbox in place.

7. Tighten all bolts except the top one between the engine and the gearbox.

Tightening torque, M10 bolts 40 Nm (30 lbf ft)

Tightening torque, M12 bolts 70 Nm (52 lbf ft)


8. D223L: Fit the coolant pipe bracket. All: Fit the charge air pipe bracket.

9. Remove the lifting tool from the gearbox and move away the jack.

10. Refit the gearbox bolts.

Tightening torque 24 Nm (18 lbf ft)

11. Undo the strap and position the power steering cooling coil in place. Make sure it is fitted on the correct side of the rubber seal.


12. Lower the car. Lift in place the power train with the lifting beam until it meets the engine mounting.

13. Fit the bracket for the engine mounting according to the marks made earlier.

Tightening torque 70 Nm +45° (52 lbf ft +45°)


14. D223L: Remove the lifting beam. B207: Remove the holder and the lifting beam.


15. Fit the three upper gearbox bolts. D223L: The bolt for the starter motor is longer than the other two.

Tightening torque 70 Nm (52 lbf ft)


16. Fit 83 95 162 Protective collar, drive shafts in the left drive shaft seal. Remove the strap. Make sure that the drive shaft is clean, lubricate it and then align it with the tool.

Important

Fit the driver in the gearbox until approx.20 mm are remaining and pull out the tool before the sealing surface of the shaft reaches the shaft seal.



17. Push in the rest of the drive shaft into the gearbox until the circlip clicks in.

18. Attach the ABS cable to the clip.

19. Fit the ground cable.


20. Place a receptacle under the car and fill with gearbox oil through the level plug hole. See Summary of lubricants and sealants . Fit the level plug.

Tightening torque 50 Nm (37 lbf ft)

21. Fit the torque rod bracket.

Tightening torque 70 Nm +90° (52 lbf ft +90°)

22. Position the subframe using the fixture. Use also a 82 93 102 Extension, 500 mm, 3/8 square to guide the subframe. Lift until the anti-roll bar can be fitted to the subframe.


23. Undo the link arm nuts and fit the anti-roll bar to the subframe.

Tightening torque 18 Nm (13 lbf ft)

24. Fit the suspension arm ball joints to the steering swivel member.

Tightening torque 50 Nm (37 lbf ft)

Important

Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.



25. Check that the guide pins fit into the reference holes, adjust the subframe until the guide pins go in easily and fit the subframe bolts and brackets.

Tightening torque, subframe: 75 Nm +135° (55 lbf ft +135°)

Tightening torque, rear subframe bolts: 90 Nm +45° (66 lbf ft +45°)


26. Fit the anti-roll bar link arms.

Tightening torque 64 Nm (47 lbf ft)

27. Move away the trolley lift and jig.

28. Fit the torque rods to the subframe.

Tightening torque 70 Nm +90° (52 lbf ft +90°)

29. Set up 83 96 152 Engine centring tool kit and check that the engine is located correctly in relation to the subframe. Remove the centring tool.


30. Fit the radiator brackets to the subframe. Remove the straps.

Tightening torque 47 Nm (35 lbf ft)


31. Fit the clamps holding the power steering pipe to the subframe.


32. Fit the steering gear to the subframe.

Tightening torque 50 Nm + 60° (37 lbf ft + 60°)


33. Fit a joint clamp on the front pipe and fit the front exhaust pipe to the catalytic converter. Use a new gasket and new nuts.

Tightening torque: 25 Nm (18 lbf ft)

34. Adjust the joint clamp so that the pipe ends are in the middle. Tighten the joint clamp nuts.

Tightening torque 40 Nm (30 lbf ft)


35. Connect the connector and the cable clip to the headlamp angle sensor (optional).


36. Fit the front wing liner section.


37. Fit the connector and hose to the headlamp washer. Fit the front spoiler shield.


38. D223L: Fit the lower engine cover. CV: Fit chassis reinforcement, front subframe, CV

39. Fit the front wheels .

40. Lower the car and fit the bumper shell upper mountings.


41. Fit the quick-release coupling to the clutch slave cylinder. Remove the hose pinch-off pliers. Make sure the connection is secured in the correct position.


42. Bleed the clutch. See Bleeding the clutch hydraulic system in the car .

43. Attach the gear cables to the gearbox.

44. Fit the reversing light switch connection and the ground cable to the engine mounting.

Tightening torque 18 Nm (13 lbf ft)

45. Fit the battery tray and the bonnet switch connector.


46. D223L: Fit the power steering fluid reservoir with bracket and the cable clamp under the battery tray.


47. D223L: Fit the cover with vacuum tank, etc.

48. Fit the battery.

49. Fit the battery cover and upper engine cover.


50. Remove the wing covers.

51. Carry out Measures after disconnecting the battery .

52. Check the gear positions and adjust if necessary as described in Adjusting gear cables .

53. Test drive the car. Check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed.