SAAB WIS ONLINE

Rattling noise from the synchromeshsleeves

SERVICE INFORMATION
Bulletin Nbr: 471-1601
Date: ........... MAJ 1995
Market: ALL
Rattling noise from the synchromesh sleeves

Cars concerned

Saab 900 M94- with 4-cylinder engine and manual gearbox up to and including serial No. J95349.

Saab 9000 M94- with 4-cylinder engine and manual gearbox up to and including serial No. J95478.

Background

On certain cars a rattling noise may occur under light acceleration and under load at engine speeds between 800 and 1,200 rpm. This noise is made by the 3rd, 4th and 5th gear synchromesh sleeves. In the event of customer complaints, the following steps can be taken.

Important

In the case of a rattling noise occurring at 1,200-2,200 rpm, see SI 471-1617.


Materials

87 43 791 Leaf spring 3rd, 4th (6 per car)

87 43 809 Leaf spring 5th (3 per car)

87 34 477 Sleeve

87 34 824 Seal

87 35 516 Nut

It is expected that the parts will be in stock by week 26.

Procedure


1. Dismantle the gearbox up to and including the input shaft, see Service Manual 4:1 "Manual gearbox" for the relevant car.

2. 3rd/4th: Fit leaf springs between the two synchromesh sleeves and the hub, see Fig.

3 leaf springs for each synchromesh sleeve.


3. 5th: Fit 3 leaf springs between the synchromesh sleeve and the hub. Hold the synchromesh sleeve and hub together with two rubber bands, see Fig., so that the leaf springs do not come loose when the hub is fitted in place.


4. Assemble the gearbox, see Service Manual 4:1 "Manual gearbox" for the relevant car, . Use a new sleeve (87 34 477) and new nut (87 35 516).

Tightening torque, reversing shaft support, 28 Nm (20.7 lbf ft).

5. Drive the car on test and check that the steps taken have had the desired effect. If the rattling noise persists, see SI 471-1617.


Standard time information

See standard time list.

Warranty information

Regular warranty rules apply.