Removal and Installation
Manual TransmissionREMOVAL
Open the front hood fully, and support with stay.
Disconnect the ground cable from battery.
Remove the intercooler.
Disconnect the following connectors:
Neutral position switch connector
Back-up light switch connector
Vehicle speed sensor
Remove the starter.
Remove the operating cylinder from transmission.
Remove the pitching stopper.
Set the ST.
ST 32005085 ENGINE SUPPORT ASSY
Separate the clutch release fork from release bearing.
Remove the clutch operating cylinder from transmission.
Remove the plug using 10 mm hexagon wrench.
(A) Shaft
(B) Bolt
Screw the 6 mm dia. bolt into release fork shaft, and then remove it.
Raise the release fork and unfasten the release bearing tabs to free release fork.
Note: Step (4) is required to prevent interference with engine when removing the engine from transmission.
Remove the bolt which holds the right upper side of transmission to engine.
Remove the center exhaust pipe.
Remove the rear exhaust pipe and muffler.
Important: When removing the exhaust pipes, be careful each exhaust pipe does not drop out.
Remove the heat shield cover. (If equipped)
Remove the hanger bracket from right side of transmission.
Remove the propeller shaft.
Remove the gear shift rod and stay from transmission.
Disconnect the stay from transmission.
(A) Stay
(B) Rod
Disconnect the rod from transmission.
Disconnect the stabilizer link from transverse link.
Remove the bolt securing ball joint of transverse link to housing.
Remove the drive shafts.
Remove the nuts which hold the lower side of transmission to engine.
Place the transmission jack under transmission.
Important: Always support the transmission case with a transmission jack.
Remove the transmission rear crossmember from vehicle.
Remove the transmission.
Note:
1. Move the transmission jack toward rear until main shaft is withdrawn from clutch cover.
2. Shrink the turnbuckle of ST while lowering the transmission jack to tilt the engine assembly backward.
Separate the transmission assembly and rear cushion rubber.
Remove the clutch release bearing from engine side..
INSTALLATION
Install the rear cushion rubber to transmission assembly.
Tightening torque: 35 Nm (3.57 kgf-m, 25.8 ft. lbs.)
Install the clutch release lever and bearing onto transmission.
Install the transmission onto engine.
Gradually raise the transmission with transmission jack.
Loosen the turnbuckle of ST to return the engine assembly to its original position.
Engage them at splines.
Note: Be careful not to strike the main shaft against clutch cover.
Install the transmission rear crossmember.
Tightening torque:
T1: 70 Nm (7.1 kgf-m, 51 ft. lbs.)
T2: 140 Nm (14.3 kgf-m, 103 ft. lbs.)
Take off the transmission jack.
Tighten the nuts which hold the lower side of transmission to engine.
Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft. lbs.)
Connect the engine and transmission.
Install the starter.
Tighten the bolt which holds right upper side of transmission to engine.
Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft. lbs.)
Remove the ST.
Install the pitching stopper.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 37 ft. lbs.)
T2: 58 Nm (5.9 kgf-m, 43 ft. lbs.)
Lift-up the vehicle.
Replace the differential side retainer oil seal.
Note: Be sure to replace the differential side retainer oil seal after the procedure of removing the front drive shaft.
Install the front drive shaft into transmission.
ST 32005040 FRONT DRIVE SHAFT OIL SEAL PROTECTOR
(A) Transverse link
(B) Ball joint
Install the ball joints of lower arm into knuckle arm of housing, and tighten the installing bolts.
Tightening torque: 49 Nm (5.0 kgf-m, 36 ft. lbs.)
Install the stabilizer link from transverse link.
Tightening torque: 30 Nm (3.1 kgf-m, 22.1 ft. lbs.)
Install the gear shift rod and stay.
(A) Stay
(B) Rod
Install the gear shift rod onto transmission.
Install the stay onto transmission.
Install the propeller shaft.
Install the heat shield cover. (If equipped)
Install the hanger bracket on right side of transmission.
Install the rear exhaust pipe and muffler.
Install the front exhaust pipe and center exhaust pipe. (Saab 9-2X 2.5i Linear)
Install the center exhaust pipe.
Install the under cover.
Push the clutch release lever to fit the bearing into clutch cover.
Install the operating cylinder.
Tightening torque: 37 Nm (3.8 kgf-m, 27.5 ft. lbs.)
Connect the following connectors:
Transmission ground cable
Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft. lbs.)
Vehicle speed sensor connector
Neutral position switch connector
Back-up light switch connector
Install the air cleaner case stay.
Tightening torque: 16 Nm (1.6 kgf-m, 11.6 ft. lbs.)
Install the air cleaner case and duct.
Connect the battery ground cable to battery.
Take off the vehicle from lift arms.