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(471-2421 utg. 2) Adjustment of gear cables, manual 6-speed transmission

Symptom: Difficult to shift from 1st gear to 2nd and from 3rd gear to 2nd.

TECHNICAL SERVICE BULLETIN
Bulletin Nbr: 471-2421 utg. 2
Date: ........... Januari 2005
Market: US/CA
Adjustment of gear cables, manual 6-speed transmission

Cars affected

Saab 9-3 (9440) M03- with transmission alternative FM67, FM68 or FM6A.

Background

The driver may experience that the gearbox is sluggish, specifically during shifting from 1st to 2nd and from 3rd to 2nd gear. The fault is due to cramped lateral spaces both in the gearbox and gear lever housing. The fault can be rectified by adjusting the gear lever.

In the case of customer complaint the following procedure must be undertaken.

Symptom description

Difficult to shift from 1st gear to 2nd and from 3rd gear to 2nd.



Procedure


1. Place the gear lever in neutral position.

2. Lift in the selector shaft enough to align 87 92 335 Lock pin in the hole in the shaft.


3. Loosen the gear lever cover with rubber mat and lift up the cover. Use 82 93 474 Removal tool.


4. Carefully press a screwdriver blade onto the cable adjuster and pry slightly towards the gear lever. An audible click means that the adjustment catch has been released. Repeat the procedure on the other cable adjuster.

5. Lock the gear lever in adjustment position by lifting the adjusting sleeve and pushing the two catches in at the same time. Use an appropriate set of pliers. Carefully release the adjusting sleeve downward and allow the left-hand catch to drop into the recess in the gear lever housing (adjustment position).


6. Move the gear lever to the left.

Note: Use a single finger to carefully move the lever to the left.

Hold it in this position and push the screwdriver against the crescent shaped section of the adjustment catch at the same time. An audible click means that the catch has fastened in the correct position. Repeat the procedure on the other cable adjuster.


7. Lift up the adjusting sleeve to its normal position and make sure the catches lock.

8. Remove the lock pin.

9. Test the gear positions.

10. Fit the gear lever cover and the rubber mat.

11. Verify operation by test driving the car.


Time/Warranty information

In the case of customer complaint and if the car is within the new car warranty period , use the following information to fill out the claim:

Failed Object: 43271

Fault/Reason code: 79

Location code: 09 (US=9)

Warranty Type (US): 01

Repair/Action code: 05

Labour Operation (US): 4327109

Labour Operation (CA): K1120

Time: 0.2 hr