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(TA471-1004) Oil leakage from 6-speed gearbox (F40)

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Bulletin Nbr: TA471-1004
Date: ........... April 2010
Market: All
Oil leakage from 6-speed gearbox (F40)

VEHICLES CONCERNED

Saab 9-3 with 6-speed manual gearbox ( F40 ).

BACKGROUND

If an oil leakage appears from the dividing line to the gearbox housing it has previously been necessary to replace the complete gearbox.

SYMPTOM DESCRIPTION

If an oil leakage appears from dividing line to the gearbox housing ensure that the leak is coming from the joint by using a crack enhancer that will clearly show the source.

Note: This action should be done before this TA is used to repair the gearbox.

ACTION

After the position of the leakage has been verified if it's coming from the sealing area then continue with this instruction :


1. Disassemble the gearbox from the car according to instruction in WIS , WIS / Trans / Manual trans / 6-speed / Repair instruction / Complete gearbox.

2. Disassemble the gear changing unit from the gearbox according to instruction in WIS WIS / Trans / Manual trans / 6-speed / Repair instruction / Gear changing unit.


3. Disassemble and split the gearbox housing.


4. Attention: Do Not forget to disassemble / re assemble the bolt inside the clutch cover.


5. Continue by removing rest of the bolts 19 pcs in total.


6. Carefully clean the dividing line on both surfaces, use Speed Cleaner P/N 3022852 or Locktite Super Clean 7063 and make sure no particles from the old sealing remain the gearbox.

Warning! Do not remove the gears and/or axles, and do not touch the shims, as this might destroy the function of the gearbox.


7. Apply the sealing compound P/N 93165267 of about 2 mm thick bead around the whole dividing area.


8. Refit the gearbox housing (18 + 1 bolts) tightening torque 25 +-5 Nm. Reassemble the gear changing unit, tightening torque 25 +-5 Nm. Refit the gearbox to vehicle according to instruction in WIS - refill with 2,4 l of oil P/N 93 165 290.

9. Test drive the car, check gearbox function and for leakage. If no visible leakage, return the car to the customer.