Page 411
432-2
Manual Transmission Control
NOTE
• Engage the slot in the ignition switch with the tab in the gear
lever housing when reinstalling the switch,
• For ignition switch replacement, no further disassembly is
required. Adjust the gear shift control as described below,
5. Raise and rotate the gear lever housing on its side. Remove the screws securing the plastic bottom cover, remove the housing. See Fig. 6.
Fig. 3. Gear lever housing nuts being removed with special
wrench, Saab tool no, 87 90370,
Fig. 6. Plastic bottom cover screws (arrows) being removed,
To remove ignition lock barrel
1. Remove the gear lever housing as described above.
Fig. 4. Cover plate screws (arrows) being removed to replace ignition switch,
2. Mount the housing in a vise and turn the key to the position shown in Fig. 7.
K
S
Fig. 7. Position of ignition key to remove lock barrel. View is from
above key,
Fig. 5. Ignition switch being removed,
MANUAL TRANSMISSION CONTROL
3. Using a stiff wire tool inserted in the hole in the housing,
push in the spring loaded pin in the housing while pulling the lock barrel out with the key. See Fig. 8.
Page 412
Manual Transmission Control
432-3
To remove gear selector rod
1. Remove the gear lever housing as describe above.
2. Loosen the clamp on the selector rod where the rod
comes through the firewall. See Fig. 10.
Fig. 8.
Ignition lock barrel pin being pushed in. Pull on the key
while pushing the pin.
NOTE
If the ignition key is missing, drill a hole in the side of the housing and drive in the pin as shown in Fig. 9.
Fig. 10. Selector rod clamp being loosened,
3. Remove the rod from inside the passenger compartment.
4. After installing the rod, adjust the gear shift control as
described below, Torque the clamp bolt.
Shift rod clamp bolt
• tightening torque
30 to 35 Nm (22 to 25 ft-Ib)
NOTE
Inspect and replace any worn rubber bushings, Worn bushings may cause hard shifting or jumping out of gear,
Fig. 9.
Ignition lock barrel being removed when key is missing
Drill hole where the punch is located,
To disassemble gear shift lever
To install ignition lock barrel
1. Remove the gear lever housing as described above.
1. Turn key in the new lock barrel to the position shown in
Fig. 7 above.
2. Remove the three screws and remove the gear shift lever. See Fig. 11.
2. Check that the tooth segment driver pins in the gear lever housing are in the correct position to accept the
lock barrel.
3. Measure and record the length of the latch stud as
shown in Fig. 12.
3. Push in the spring loaded pin on the lock barrel and insert the barrel in the gear lever housing until it clicks.
MANUAL TRANSMISSION CONTROL
Page 413
432-4
Manual Transmission Control
Fig. 11. Gear shift lever being removed after removing screws lo
Fig. 13. Gear shift lever being disassembled.
cated at arrows,
CAUTION
The latch stud prevents the shift lever from accidentally going
into reverse when attempting to shift into 5th gear. The length
of the latch stud must not be altered or the lockout feature may
not work.
Fig. 14. Gear shift lever latch stud being unscrewed.
6. Inspect and replace any worn components. Adjust the
latch stud projecting length to the value given above.
See Fig. 12.
7. Reassemble the lever and housing. Grease all sliding
Fig. 12. Gear shift lever latch stud being measured. The length is
adjustable.
components with soft EPI grease. See Fig. 15 for an
exploded view of thE! assembly.
To adjust gear shift control (up to mid 1986)
Gear shift lever latch stud
• projecting length
22±O.5 mm (55/64 in.)
4. Remove the wire clip, sleeve, spring, and bearings.
See Fig. 13.
5. Unscrew the latch stud from the rod. See Fig. 14. Re··
move the rubber bellows and shift knob.
MANUAL TRANSMISSION CONTROL
1. Remove just the console as described earlier. Engage
reverse gear, and release the clamp on the shift rod.
See Fig. 10 above.
2. Lock the gear shift lever in position by inserting a 6 mm
(1/4 in.) pilot tool in the hole as shown in Fig. 16.
NOTE
A drill bit or drift works well as a pilot tool.
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Manual Transmission Control
432-5
To adjust gear shift control (from mid 1986)
,
Tool required
. .':ll=~--"?-c::==========::::::t
'"
• shift rod alignment tool .... Saab tool no. 87 91 576
1
10
1. Remove only the console as described earlier under
3
1. Shift knob
2. Gear lever
3. Sleeve
4. Latch rod
5. Rubber bellows
6. Plate
7. Bearing
8. Spring
9. Wire clip
10. Spring
removing the gear selector housing. Engage third gear
and insert the special tool in the differential cover as
shown in Fig. 17.
11. Latch stud
12. Carrier
13. Bearing
Fig. 15. Gear shift lever assembly exploded view.
Fig. 17. Shift rod alignment tool (arrow) installed in back of differential cover. Shift lever must be in third gear.
2. Loosen the shift rod clamp bolt. See Fig. 10 above.
3. Lock the gear shift lever in third gear by inserting a 6
mm (1/4 in.) pilot tool in the hole as shown in Fig. 18.
Fig. 16. Gear shift lever being locked into reverse prior to tightening shift rod
clamp. Turbo model shown with console bellows (arrow) removed. other
models are similar.
3. Tighten the clamp on the shift rod to the torque given
below. Remove the pilot tool and reinstall the console.
Fig. 18. Gear shift lever being locked in 3rd gear prior to tightening
shift rod clamp.
Shift rod clamp bolt
• tightening torque
30 to 35 Nm (22 to 25 ft-Ib)
MANUAL TRANSMISSION CONTROL
Page 415
432-6
Manual Transmission Control
NOTE
A drill bit or drift works well as a pilot tool.
4. Tighten the shift rod clamp. Remove the special tool
'from the differential cover and remove the pilot tool.
Reinstall the console.
Tightening torque
• Shift rod clamp bolt. .... 30 to 35 Nm (22 to 25 ft-Ib)
A
A
To adjust centering of gear shift lever in
neutral gate (up to rrlid 1986 only)
The gear shift lever is in its proper neutral position if it can
be shifted straight forward into third gear without having to
''fish'' around for the gear. No adjustment can be done on models from mid 1986 on.
1. To adjust models up to mid 1986, pull the carpeting
away from the front of the shift lever, then engage third
gear.
2. Loosen the two retainer screws. Move the bracket so the
rollers drop into the plastic block grooves. See Fig. 19.
87034
Fig. 19. Gear shift centering mechanism retainer screws A and rollers
B. Adjustment is done with gearshift in 3rd gear
3. Tighten the retaining screws and recheck the adjustment as described above. Reinstall the console pieces.
Page 416
Automatic Transmission Controls
444-1
444 Automatic Transmission Controls
Transmission Controls
To check shift lever and linkage
To remove gear selector cable
To install and adjust gear selector cable
444-1
444-1
444-1
444-2
To remove and install transmission
throttle cable
To adjust transmission throttle cable
To remove governor
444-2
444-3
444-4
TRANSMISSION CONTROLS
To check shift lever and linkage
1. Move the selector lever to the N position. Press the
pawl button and move the lever slightly back and forth.
2. Release the pawl button and check that the lever is positioned exactly at position N. If not, then adjust the
gear selector cable as described below.
CAUTION
Correct adjustment of the gear selector cable is vital to the
functioning and life of the transmission.
Fig. 1. Shift indicator plate being moved to reveal cover screw (arrow) below, Screw on opposite side (not shown) must also
be removed.
To remove gear selector cable
Tool required
• gear selector housing wrench no. 8790370
Saab tool
1. Disconnect the negative (-) battery cable. Move the
front seats to their fully rear position. Apply the handbrake.
2. Move the gear selector to P and remove the ignition
key.
Ag.2. Gear selector housing console being removed,
3. Remove the indicator plate and slide it toward the shift
knob. See Fig. 1.
4. Remove the cover screws and slide the plastic console
up enough to disconnect the wires to the interior light
switch. Remove the console. See Fig. 2.
5. Working at the transmission, remove the cable retaining bolt. See Fig. 3.
6. Slide back the spring loaded cable sleeve and unhook
it from the transmission shift rod. See Fig. 4.
7. Remove the gear selector housing nuts using special
Saab wrench no. 87 90 370. Rotate the housing onto
its side then remove the circlip and pin from the end of
the cable.
Fig. 3. Transmission cable retaining bolt (arrow),
TRANSMISSION CONTROLS
Page 417
444-2
Automatic Transmission Controls
1. Install the new cable and check for a proper seal where
the cable passes through the firewall.
2. Hook the cable to the transmission shift rod in the
transmission, then insert the cable into the transmission case and install the retaining bolt to the case.
3. In the car, install the end of the cable into the selector
lever hole and secure with the pin and circlip. Tighten
the cable jacket nuts.
4. Withdraw the wire in the cable as far as possible, corresponding to position P as if the cable were attached
to the shift lever. Move the cable in two notches corresponding to position N.
Fig. 4. Transmission cable being unhooked from transmission
shift rod. Shift lever must be in P.
8. Remove the setscrew that secures the cable to the lever. See Fig. 5. Loosen the cable jacket nuts and remove the cable.
5. Move the gear selector to position N without disturbing
the cable position. Install and tighten the cable setscrew. See Fig. 5 above.
Tightening torque
• Cable setscrew
NOTE
The cable jacket nuts hold the cable to the bottom of the shift
lever housing.
2.5 Nm (23 in-Ib)
6. Install the gear selector housing nuts using the special
Saab wrench no. 8790370.
CAUTION
The gear selector housing must be securely fastened to the
floor console.
7. Perform a final check by moving the selector lever to
position D. Release the pawl button and move the lever
to position 2. Increasing resistance should be felt in
both directions. Slight movement should be felt before
the lever is locked by the selector lever housing detent.
If not, then the cable is not adjusted correctly.
The remaining is the reverse of removal. Be sure to check
the operation of the neutral safety switch, interior lighting
switch and the parking pawl.
Fig. 5. Transmission cable setscrew being removed using internal-hex head wrench. Housing removed from car for
clarity.
9. Remove the carpeting, heater duct, and the old cable.
To install and adjust gear selector cable
NOTE
Proper transmission operation and service life depends on the
correct adjustment of the selector cable.
TRANSMISSION CONTROLS
To remove and install transmission throttle
cable
The transmission throttle cable enters the transmission below the torque converter on the driver's side. It moves a cam in
the transmission valve body. After replacment, the cable must
be adjusted and the ATF must be topped up.
1. Disconnect the cable from the throttle lever and from its
attachment to the retaining plate on the throttle housing.
2. Drain the ATF from the transmission and remove the
forward sump cover. See 472 Automatic Transmission Seals and Gaskets. Remove the ATF strainer.
Page 418
Automatic Transmission Controls
444-3
CAUTION
• Do not dislodge any of the pipes in the valve body. The transmission will have to be removed from the car to reinstall these
pipes.
• Do not allow any dirt to enter the transmission, or damage
may result.
3'. Detach the throttle cable from the cam on the control
valve at the valve body. See Fig. 6. Unscrew the cable
from the transmission housing. See Fig. 7.
Fig. 8. stop clip (arrow) being clamped on a new cable. The cable must be straight and slightly tensioned against cam in
valve body.
6. Connect the cable to the throttle housing. Floor the ac
celerator pedal and adjust the nuts until the highest
point of the cam on the control valve is aligned as
shown in Fig. 9. This is the kickdown position.
I
-UJ
valve----~
Fig. 6. Transmission throttle cable being unhooked from cam at
valve body.
Cam-
i
I
II
I
"
87156·S4l195
Fig. 9. Cam in valve body in kickdown position for initial throttle cable
adjustment at throttle housing.
The remaining is the reverse of removal. Use a new ATF
strainer if clogged or damaged. Install a new sump gasket and
refill the transmission with new ATF. Check and correct any
binding in the accelerator pedal linkage. Finally, do the precision adjustment described below.
Fig. 7. Transmission throttle cable being unscrewed from transmission housing.
4. Connect a new cable to the transmission housing.
Hook the cable end onto the cam at the control valve at
the valve body. Make sure that the cable wire is seated
in the cam guide.
5. Working at the other end of the cable, straighten the cable and pull the wire until slight tension ot the cam is
felt. Using pliers, clamp the stop clip next to the threaded cable sheath. See Fig. 8.
To adjust transmission throttle cable
Precise adjustment of the cable should be done after installation of a new cable or if the kickdown function is inoperative.
A helper is needed to complete the adjustment procedure.
Tool required
• ATF pressure gauge equivalent
Saab tool no. 8791 592 or
TRANSMISSION CONTROLS
Page 419
444-4
Automatic Transmission Controls
1. Remove the pressure tap on the transmission and install the pressure gauge. See 400 TransmissionGeneral for information on performing a pressure test.
4. Remove the pan by rotating it 1/8 of a turn to gain clearance around the cross member. See Fig. 10.
2. Block the wheels and apply the handbrake. Start the
engine and check for correct idle speed with the gear
selector in position P.
3. Disconnect the transmission throttle cable from the
throttle lever.
4. Firmly apply the footbrake. Engage D with the selector
lever. Pull and release the cable wire several times.
Record the gauge pressure with the wire released.
NOTE
If pressure does not return to the same value, the control
valve in the valve body may be sticking and needs to be
cleaned.
Fig. 10. ATF sump pan being removed from car.
5. Reconnect the cable to the throttle lever. Line pressure
should increase by 0.1 bar (1.5 psi). If pressure does
not increase by 0.1 bar (1.5 psi), adjust the cable at the
throttle lever while watching the pressure gauge. The
correct pressure values are given below.
5. Remove the two screws and remove the governor. See
Fig. 11.
Line pressure
• 4.2 to 4.9 bar (61 to 71 psi)
To remove governor
The governor controls when the transmission shifts. Most
problems with the governor occur from dirty ATF. See 400
Transmission-General for more information on troubleshooting the governor.
The governor can be removed without disassembling the
transmission. Extreme cleanliness must be observed when
installing the sump cover. Refill the transmission with ATF as
described in 1 LUBRICATION AND MAINTENANCE.
1. Apply the handbrake and block the wheels. Set the selector lever to N. Drain the automatic transmission fluid.
NOTE
Do not drain the final drive fluid.
2. Remove the support member under the sump.
3. Clean the bottom part of the transmission around the
rear sump pan. Remove the sump bolts.
TRANSMISSION CONTROLS
Fig. 11. Governor being removed from transmission.
NOTE
To gain access to the governor screws, rotate one of the
wheels while holding the other stationary. This will change the
position of the governor.
Installation is the reverse of removal. Be sure the cover
plate for the governor faces toward the pinion bearing housing. Reinstall the ATF sump pan with a new gasket. See 472
Automatic Transmission Seals and Gaskets. Fill the transmission with new fluid, and check for leaks.
Tightening torques
• ATF sump pan bolts .... 8 to 12 Nm (71 to 106 in-Ib)
• ATF sump pan drain plug .. 5 to 8 Nm (44 to 71 in-Ib)
Page 420
Automatic Transrnission Seals and Gaskets
472 Automatic Transmission
and Gaskets
General
Automatic Transmission Pan Gasket
472-1
472-1
GENERAL
This repair group covers replacement of the automatic
transmission pan (sump) gasket and replacement of the automatic transmission fluid cooler only. Other automatic transmission gaskets and seals require disassembly of the
transmission, which is not covered in this manual.
Automatic Transmission Pan Gasket
The gaskets used on sump pans are easily replaced in the
car by removing the bolts around the pan. See Fig. 1. Refill the
sump with new ATF, then start the car and select P for 15 seconds, select D for 15 seconds and select R for 15 seconds to
circulate the ATF. Reselect P and check the fluid level at idle.
Shut off the engine and check for leaks.
WARNING
Always firmly apply the handbrake before starting the engine.
472-1
eals
Automatic Transmission Fluid Cooler
To replace ATF cooler
472-2
472-2
Tightening torques
• ATF sump pan bolts ... 8 to 12 Nm (71 to 106 in-Ib)
• ATF sump pan
drain plug
5 to 8 Nm (44 to 71 in-Ib)
Automatic Transmission Specifications
• Grade of ATF-Ford Specification M2C-33F
(alternate: Ford Specification G)
• ATF capacity 8.5 quarts (8.0 liters)
CAUTION
• Use only Ford spec M2C-33F/G ATF. Do not use other types
of fluid.
• Do not allow any dirt to enter the transmission or damage
may result.
Other areas where leakage can occur are at the torque
converter-to-ATF pump seal and at the front cover gasket.
The pump seal is integral with the ATF pump housing. Replacing this seal requires that the front cover, primary chain
and sprocket, and the ATF pump be removed from the transmission housing.
The pinion bearing housing seals can leak allowing ATF
and final drive fluid to mix. The only remedy is to disassemble
the transmission and replace the seals. Special tools and
techniques are required for the above procedures and are
best left to an authorized Saab dealer.
Fig. 1. ATF front cover sump bolts being removed, Rear sump
cover can be seen in background. The ATF drain plug is
located at A,
GENERAL
::}::::::;::::::.:.:.....
~~~~~~~~t~~~~~~~~~~~~t