Recall - Reverse Gear Shift Linkage Adjustment: Overview

CATEGORY
Recall

SECTION
9

PAGE
17

ISSUE
07/95-0595

CODE
432

Subject:
Recall 296 Adjustment of Reverse Gear Engagement

Application:
1994-95 900 with Manual Transmission
(excluding 1994 900 Convertibles)
VIN Serial No. Ranges R2000001 - R2047576,
S2000001 - S2006999, S7000001 - S7011962

Safety - related
1994-95 900 Models with Manual Transmission
(Excludes 1994 900 Convertible Models)
NHTSA 95V - 068

The Campaign

Saab Cars USA, Inc. has notified the National Highway Traffic Safety Administration (NHTSA) that a defect which relates to motor vehicle safety may exist in certain 1994-1995 900 models equipped with manual transmissions. (1994 900 Convertibles are excluded from this campaign.)

On certain 1994-95 900 models with manual transmissions it is possible that an improperly adjusted shift linkage could lead to the reverse gear not actually being engaged in the transmission. This campaign calls for the inspection of the shift linkage and the addition of four washers. A revised service adjustment procedure will also be performed that will ensure when the shifter is moved to the reverse position, that the reverse gear is actually engaged.

Cars Affected:

1994-95 900 models (excluding 1994 Convertibles) with manual transmission within the following VIN Serial No. Ranges:

R2000001 - R2047576
S2000001 - S2006999
S7000001 - S7011962

Recall Schedule:

Dealer Notification (DCS E-Mail) April 5, 1995
Saab Press Release April 17, 1995
PSI Bulletin issued June 20, 1995
Owner Notification July 1, 1995
Start of Repairs July 15, 1995

Parts:

Washers (8) 40 87 862
(NOTE: 4 per car required)

An initial parts order of washers equal to 25% of the vehicles appearing on your Status List will be released automatically to you commencing the week of June 26, 1995. Additional quantities should be ordered using VOR ordering procedures.

Action:

1. Remove the gear linkage from the gearbox and gear rod.





2. Remove the circlips as shown in Figure 1, item A.

3. Remove the two 2 mm washers (Figure 1, item A) from the linkage and fit the four new ones (1 mm) as shown in Figure 1, item B.

4. Fit the linkage to the gearbox.

NOTE:
Two people are needed to carry out the adjustment procedure described in points 5-13. This method replaces the one shown in Service Manual 4:1 Manual gearbox, p. 432-4. Please make a note of this correction to that manual.

5. Engage reverse gear and remove the ignition key.





6. Undo the clamp securing the gear rod to the gearbox linkage. See Figure 2, item 6.

7. Lift up the gear lever boot. See Figure 2, item 7.

8. Insert a 3 mm feeler gauge between the gear lever and the reverse gear detent. See Figure 2, item 8.

9. Press the gear lever lightly forward against the stop and the feeler gauge. Hold the gear lever in this position while carrying out points 10 and 11.

10. Press the entire gear linkage against the gearbox so that the reverse gear is positively engaged. Release the linkage. See Figure 2, item 10.

11. Tighten the clamp securing the gear rod to the linkage. See Figure 2, item 11.

Tightening torque: 21 Nm (15.5 ft.lbs.)

12. Release the gear lever and remove the feeler gauge.

13. Check that 5th gear can easily be engaged and that the ignition key can be turned to the LOCK position and removed from the ignition switch with gear lever in reverse.

Is 5th gear easy to engage? Can the ignition key be removed when the ignition switch is in the LOCK position and the gear lever in reverse?

YES - The adjustment is correct.

NO - Repeat the whole procedure using a thicker feeler gauge (3.5 mm).

Warranty Information:

When submitting a Recall 296 Campaign claim, the following information must be included on the claim:

Failure Code: 10296-79-0-05-01.
Recall Action Code (RAC) = 3 must be used.

Operation No.: 10296 for 0.6 hr.

The following information must be added to your DCS Table:

Failed Part: 10296
Operation No.: 10296
Engine type = 9
Trans. type - M
Begin: 94
End: 95





After the car has been modified, mark the campaign plate in position C4 using a numeral "8" (Saab Special Tool P/N 02 97 713). Order this special tool directly from Kent-Moore at 1-800-345-2233.