Automatic Transmission: Removal & Installation Saab 9-2X I

REPLACEMENT

Lift-up the vehicle.

Drain the ATF completely.

Check the ATF for condition.

Replace with a new gasket, and then tighten the ATF drain plug.

Tightening torque

25 Nm (2.5 kgf-m, 18.1 ft-lb)

Scheme 109

1. Oil pan
2. Drain plug (ATF)
3. Differential gear oil drain plug

Lower the vehicle.

Pour ATF into the oil charge pipe.

Recommended fluid

Dexron III type automatic transmission fluid

Capacity

Fill the same amount of ATF drained from drain plug hole.

Capacity when transmission is overhauled

9.3 - 9.6 liters (9.8 - 10.1 US qt, 8.2 - 8.4 Imp qt)

Check the level and leaks of ATF.

Lift-up the vehicle.

Remove the differential gear oil drain plug using TORX(R) T70, and then drain the differential gear oil completely.

Replace the gasket with a new one, and then tighten the differential gear oil drain plug using TORX(R) T70.

Tightening torque

70 Nm (7.1 kgf-m, 51.6 ft-lb) (Copper gasket)

44 Nm (4.5 kgf-m, 32.5 ft-lb) (Aluminum gasket)

Scheme 110

1. Oil pan
2. Drain plug (ATF)
3. Differential oil drain plug

Lower the vehicle.

Pour gear oil into the gauge hole.

Recommended fluid

Gear oil capacity

1.1 - 1.3 liters (1.2 - 1.4 US qt, 1.0 - 1.1 Imp qt)

Check the level of differential gear oil.

REMOVAL

Set the vehicle on a lift.

Open the front hood fully, and support it with a stay.

Disconnect the battery ground cable.

Remove the air intake chamber. (Saab 9-2X 2.5i Linear)

Remove the air cleaner case or air intake chamber. (Saab 9-2X 2.5i Linear)

Remove the intercooler. (Saab 9-2X 2.0T Aero)

Remove the air cleaner case stay. (Saab 9-2X 2.5i Linear)

Scheme 111

Disconnect the following connectors.

Transmission harness connector

Scheme 112

Transmission ground terminal

Remove the starter.

Remove the pitching stopper.

Scheme 113

Separate the torque converter clutch from drive plate.

Install the V-belt cover.

Remove the service hole plug.

Remove the bolts which hold the torque converter clutch to drive plate.

While rotating the engine, remove the other bolts using ST.

1. Saab 9-2X 2.5i Linear ST 32005163 CRANK PULLEY WRENCH
2. Saab 9-2X 2.0T Aero ST 32005164 CRANK PULLEY WRENCH

Scheme 114

Install the ST to converter case.

ST 32005099 STOPPER SET

Scheme 115

Remove the ATF level gauge.

Note. Plug the opening to prevent the entry of foreign particles into transmission fluid.

Scheme 116

Remove the pitching stopper bracket.

Set the ST.

ST 32005085 ENGINE SUPPORT BRACKET

Scheme 117

Remove the bolt which holds the upper side of transmission to engine.

Scheme 118

Lift-up the vehicle.

Remove the under cover.

Remove the front, center, rear exhaust pipe and muffler. (Saab 9-2X 2.5i Linear)

Remove the center and rear exhaust pipes, and muffler. (Saab 9-2X 2.0T Aero)

Remove the heat shield cover. (If equipped)

Scheme 119

Drain ATF to remove the ATF drain plug.

Scheme 120

1. Oil pan
2. Drain plug (ATF)
3. Differential gear oil drain plug

Disconnect the ATF cooler hoses from pipes of transmission side, and remove the oil charge pipe.

Scheme 121

Remove the propeller shaft.

Remove the shift select cable.

Disconnect the stabilizer link from transverse link.

Remove the bolt securing ball joint of transverse link to housing.

Scheme 122

Pull out the front drive shaft from transmission.

Using a tire lever or a pinch bar, etc., pull out the front drive shaft until its joint facing to transmission can move smoothly.

Note. Place cloth between tire lever or pinch bar and transmission in order to avoid damaging the side retainer of transmission.

Hold the transmission side joint portion of front drive shaft by hand and extract the housing from the transmission by pressing it outside so as not to stretch the boot.

Remove the bolts which hold the clutch housing cover.

Remove the nuts which hold the lower side of transmission to engine.

Scheme 123

Place the transmission jack under transmission.

Note. Make sure that the support plates of transmission jack don 't touch the oil pan.

Remove the transmission rear crossmember from vehicle.

Scheme 124

While gradually lowering the transmission jack, fully contact the engine support, and then tilt the engine rearward.

Remove the transmission.

Scheme 125

Separate the transmission assembly and rear cushion rubber.

INSTALLATION

Replace the differential side oil seal with new one.

Note. Replacement is not necessary when new oil seal has been installed.

Install the rear cushion rubber to transmission assembly.

Tightening torque

39 Nm (4.0 kgf-m, 29 ft-lb)

Install the ST to converter case.

ST 32005099 STOPPER SET

Scheme 126

Install the transmission onto engine.

Gradually raise the transmission with transmission jack.

Scheme 127

Engage them at splines.

While gradually lifting the transmission jack, turn the screw of engine support, and then tilt the engine forward.

Install the transmission rear crossmember.

Tightening torque

T1: 35 Nm (3.6 kgf-m, 26 ft-lb)

T2: 70 Nm (7.1 kgf-m, 51 ft-lb)

Scheme 128

Take off the transmission jack.

Tighten the nuts and bolts which hold the lower side of transmission to engine.

Tightening torque

50 Nm (5.1 kgf-m, 36.9 ft-lb)

Scheme 129

Tighten the bolt of clutch housing cover.

Lower the vehicle.

Connect the engine and transmission.

Remove the ST from converter case.

Note. Be careful not to drop the ST into the converter case when removing ST.

ST 32005099 STOPPER SET

Install the starter.

Tighten the bolt which holds the upper side of transmission to engine.

Tightening torque

50 Nm (5.1 kgf-m, 36.9 ft-lb)

Scheme 130

Install the torque converter clutch to drive plate.

Tighten the bolts which hold the torque converter clutch to drive plate.

Tighten the other bolts while rotating the engine by using ST.

1. Saab 9-2X 2.5i Linear ST 32005163 CRANK PULLEY WRENCH
2. Saab 9-2X 2.0T Aero ST 32005164 CRANK PULLEY WRENCH

Tightening torque

25 Nm (2.5 kgf-m, 18.1 ft-lb)

Scheme 131

Clog the plug onto service hole.

Install the V-belt cover.

Remove the STs.

ST 32005085 ENGINE SUPPORT BRACKET

Scheme 132

Install the pitching stopper bracket.

Tightening torque

41 Nm (4.1 kgf-m, 30.0 ft-lb)

Install the pitching stopper.

Tightening torque

T1: 50 Nm (5.1 kgf-m, 37 ft-lb)

T2: 58 Nm (5.9 kgf-m, 43 ft-lb)

Scheme 133

Lift-up the vehicle.

Replace the snap ring of front drive shaft with a new one.

Apply grease to the oil seal lips.

Install the ST to side retainer.

ST 32005040 OIL SEAL PROTECTOR

Scheme 134

Align the spline of front differential shaft to that of differential bevel gear for insertion, and remove them using ST.

ST 32005040 OIL SEAL PROTECTOR

Insert the front drive shaft into transmission securely by pressing the front housing from outside.

Scheme 135

Install the ball joint into housing.

Connect the stabilizer link to transverse link, and tighten the bolts.

Note. Discard the loosened self-locking nut and replace with a new one.

Tightening torque

T1: 30 Nm (3.1 kgf-m, 22.4 ft-lb)

T2: 50 Nm (5.1 kgf-m, 37 ft-lb)

Scheme 136

Install the shift select cable onto select lever.

Install the oil charge pipe, and connect the ATF cooler hoses to pipe.

Scheme 137

Install the propeller shaft.

Install the heat shield cover. (If equipped)

Scheme 138

Install the rear exhaust pipe and muffler assembly.

Saab 9-2X 2.5i Linear

Saab 9-2X 2.0T Aero

Install the front and center exhaust pipe. (Saab 9-2X 2.5i Linear)

Install the center exhaust pipe. (Saab 9-2X 2.0T Aero)

Install the under cover.

Lower the vehicle.

Install the ATF level gauge.

Scheme 139

Connect the following connectors.

Transmission harness connectors

Transmission ground terminal

Install the air cleaner case stay.

Tightening torque

16 Nm (1.6 kgf-m, 11.6 ft-lb)

Install the air cleaner case or air intake chamber. (Saab 9-2X 2.5i Linear)

Install the air intake chamber. (Saab 9-2X 2.5i Linear)

Install the intercooler. (Saab 9-2X 2.0T Aero)

Connect the battery ground cable.

Fill ATF up to the middle of the "COLD" side on level gauge by using oil charge pipe.

Take off the vehicle from lift arms.

Check select lever operation.

Bleed air from control valve. (Saab 9-2X 2.5i Linear)

Check the ATF level.

Perform the advance operation of learning control. (Saab 9-2X 2.5i Linear)

Check the road test.

Clean the transmission exterior.

Drain the ATF completely.

Note. Tighten the ATF drain plug after draining the ATF. Use a new gasket.

Tightening torque

25 Nm (2.5 kgf-m, 18.1 ft-lb)

Scheme 140

1. Oil pan
2. Drain plug (ATF)
3. Differential gear oil drain plug

Remove the rear exhaust pipe and muffler.

Saab 9-2X 2.5i Linear

Saab 9-2X 2.0T Aero

Remove the heat shield cover. (If equipped)

Remove the propeller shaft.

Using the ST, remove the oil seal.

ST 32005071 PULLER ASSY

Using the ST, install the oil seal.

ST 32005087 INSTALLER

Install the propeller shaft.

Install the heat shield cover. (If equipped)

Install the rear exhaust pipe and muffler.

Saab 9-2X 2.5i Linear

Saab 9-2X 2.0T Aero

Pour ATF and check the ATF level.

Lift-up the vehicle.

Remove the front exhaust pipe and center exhaust pipe.

Saab 9-2X 2.5i Linear

Saab 9-2X 2.0T Aero

Drain the differential gear by removing differential gear oil drain plug.

Scheme 141

1. Oil pan
2. Drain plug (ATF)
3. Differential gear oil drain plug

Replace new gasket and tighten the differential oil drain plug.

Tightening torque

70 Nm (7.1 kgf-m, 51.6 ft-lb)

Separate the front drive shaft from transmission.

Remove the differential side retainer oil seal using driver which wrapped with vinyl tape or etc.

Using ST, install the differential side retainer oil seal by slightly tapping with hammer.

ST 32005024 DIFFERENTIAL SIDE OIL SEAL INSTALLER

Scheme 142

Apply oil to the oil seal lips.

Using the ST, install the front drive shaft.

ST 32005040 OIL SEAL PROTECTOR

Install the front exhaust pipe and center exhaust pipe.

Saab 9-2X 2.5i Linear

Saab 9-2X 2.0T Aero

Lower the vehicle.

Pour differential gear oil into the gauge hole.

Recommended gear oil

Differential gear oil capacity

1.1 - 1.3 liters (1.3 - 1.4 US qt, 1.0 - 1.1 Imp qt)

Check the gear oil amount.

Set up the vehicle on a lift.

Move the select lever to "N" range.

Remove the air intake chamber. (Saab 9-2X 2.5i Linear)

Remove the intercooler. (Saab 9-2X 2.0T Aero)

Disconnect the inhibitor switch connector.

Scheme 143

1. Inhibitor switch

Remove the inhibitor switch connector from stay.

Lift-up the vehicle.

Remove the front and center exhaust pipes.

Remove the snap pin and washer from range select lever.

Scheme 144

1. Range select lever
2. Snap pin
3. Select cable
4. Washer

Remove the plate assembly from transmission case.

Scheme 145

1. Select cable
2. Plate ASSY

Remove the bolts.

Scheme 146

1. Inhibitor switch

Move the range select lever to parking position (left side).

Scheme 147

1. Range select lever

Remove the inhibitor switch from transmission.

Scheme 148

1. Inhibitor switch

Disconnect the inhibitor switch harness connector from inhibitor switch.

Connect the inhibitor switch harness connector to inhibitor switch.

Install the inhibitor switch to transmission case.

Scheme 149

1. Inhibitor switch

Move the range select lever to neutral position.

Using the ST, tighten the bolts of inhibitor switch.

ST 32005129 STOPPER PIN

Tightening torque

3.5 Nm (0.36 kgf-m, 2.6 ft-lb)

Scheme 150

1. Inhibitor switch
2. Range select lever

Install the select cable to range select lever.

Install the plate assembly to transmission.

Tightening torque

T: 25 Nm (2.5 kgf-m, 18.1 ft-lb)

Scheme 151

1. Select cable
2. Plate ASSY

Install the washer and snap pin to range select lever.

Scheme 152

1. Range select lever
2. Snap ring
3. Select cable
4. Washer

Install the front and center exhaust pipes. (Saab 9-2X 2.5i Linear)

Install the center exhaust pipe. (Saab 9-2X 2.0T Aero)

Lower the vehicle.

Install the inhibitor switch connector from stay.

Connect the inhibitor switch connector.

Scheme 153

1. Inhibitor switch

Install the air intake chamber. (Saab 9-2X 2.5i Linear)

Install the intercooler. (Saab 9-2X 2.0T Aero)

Inspect the inhibitor switch.

Set up the vehicle on a lift.

Disconnect the ground cable from battery.

Remove the air intake chamber. (Saab 9-2X 2.5i Linear)

Remove the intercooler. (Saab 9-2X 2.0T Aero)

Disconnect the transmission connector.

Scheme 154

1. Transmission connector

Remove the pitching stopper.

Remove the transmission connector from stay.

Lift-up the vehicle.

Clean the transmission exterior.

Drain the ATF completely.

Note. Tighten the ATF drain plug after draining the ATF. Use a new gasket.

Tightening torque

25 Nm (2.5 kgf-m, 18.1 ft-lb)

Scheme 155

1. Oil pan
2. Drain plug (ATF)
3. Differential gear oil drain plug

Remove the front, center, exhaust pipes and muffler. (Saab 9-2X 2.5i Linear)

Remove the center, rear exhaust pipe and muffler. (Saab 9-2X 2.0T Aero)

Remove the shield cover. (If equipped)

Remove the propeller shaft.

Place the transmission jack under transmission.

Note. Make sure that the support plates of transmission jack don't touch the crossmember.

Remove the transmission rear crossmember bolts.

Scheme 156

Lower the AT jack.

Note. Do not separate the AT jack and transmission.

Remove the oil cooler inlet and outlet pipe.

Note. When removing the outlet pipe, be careful not to lose balls and springs used with retaining screws.

Remove the front and torque converter turbine speed sensor.

Scheme 157

1. Front vehicle speed sensor
2. Torque converter turbine speed sensor

Remove the rear vehicle speed sensor. (Saab 9-2X 2.0T Aero)

1. Rear vehicle speed sensor

Disconnect the connector from rear vehicle speed sensor. (Saab 9-2X 2.5i Linear)

Scheme 158

1. Rear vehicle speed sensor

Remove the oil pan.

Remove the duty solenoids connector and ATF temperature sensor. Remove the connectors from clip and disconnect the connectors. (Saab 9-2X 2.0T Aero)

Scheme 159

1. Lock-up duty solenoid (Blue)
2. Low clutch timing solenoid (Gray)
3. Line pressure duty solenoid (Red)
4. Shift solenoid 2 (Yellow)
5. Shift solenoid 1 (Green)
6. 2-4 brake timing solenoid (Black)
7. 2-4 brake duty solenoid (Red)
8. ATF temperature sensor
9. Transfer duty solenoid (Brown)
10. Transmission ground

Disconnect the harness connector and transmission ground terminal. (Saab 9-2X 2.5i Linear)

Scheme 160

1. Transmission ground
2. Harness connector

Remove the harness assembly.

Pass the harness assembly through the hole in the transmission case.

Scheme 161

Connect the harness connectors.

Connect the connectors of same color, and secure the connectors to valve body using clips. (Saab 9-2X 2.0T Aero)

Tightening torque (Transmission ground cable and ATF temperature sensor)

8 Nm (0.8 kgf-m, 5.8 ft-lb)

Scheme 162

1. Lock-up duty solenoid (Blue)
2. Low clutch timing solenoid (Gray)
3. Line pressure duty solenoid (Red)
4. Shift solenoid 2 (Yellow)
5. Shift solenoid 1 (Green)
6. 2-4 brake timing solenoid (Black)
7. 2-4 brake duty solenoid (Red)
8. ATF temperature sensor
9. Transfer duty solenoid (Brown)
10. Transmission ground

Connect the harness connector and transmission ground. (Saab 9 -2X 2.5i Linear)

Tightening torque

8 Nm (0.8 kgf-m, 5.8 ft-lb)

Scheme 163

1. Transmission ground
2. Harness connector

Apply proper amount of liquid gasket to the entire oil pan mating surface.

Fluid packing

THREE BOND 1217B (Part No. 32005004)

Scheme 164

Apply liquid gasket fully to three holes other than screw holes on transmission case.

Fluid packing

THREE BOND 1217B (Part No. 32005004)

Scheme 165

Install the oil pan.

Tightening torque

5 Nm (0.5 kgf-m, 3.6 ft-lb)

Connect the connector of rear vehicle speed sensor. (Saab 9-2X 2.5i Linear)

Scheme 166

1. Rear vehicle speed sensor

Install the rear vehicle speed sensor. (Saab 9 -2X 2.0T Aero)

1. Rear vehicle speed sensor

Install the front vehicle speed sensor and torque converter turbine speed sensor, and then fasten the harness.

Tightening torque

7 Nm (0.7 kgf-m, 5.1 ft-lb)

Scheme 167

1. Front vehicle speed sensor
2. Torque converter turbine speed sensor

Install the oil cooler pipes.

Note. Be sure to use a new copper washer.

Tightening torque

T1: 25 Nm (2.5 kgf-m, 18.1 ft-lb)

T2: 45 Nm (4.6 kgf-m, 33 ft-lb)

Scheme 168

Install the transmission rear crossmember bolts.

Tightening torque

70 Nm (7.1 kgf-m, 51 ft-lb)

Install the propeller shaft.

Install the shield cover. (If equipped)

Install the front, center, rear exhaust pipes and muffler. (Saab 9-2X 2.5i Linear)

Install the center, rear exhaust pipes and muffler. (Saab 9-2X 2.0T Aero)

Lower the vehicle.

Install the transmission connector to the stay.

Install the pitching stopper.

Install the air intake chamber. (Saab 9-2X 2.5i Linear)

Install the intercooler. (Saab 9 -2X 2.0T Aero)

When removing the torque converter turbine speed sensor, refer to " FRONT VEHICLE SPEED SENSOR ".

When installing the torque converter turbine speed sensor, refer to " FRONT VEHICLE SPEED SENSOR ".

Saab 9-2X 2.0T Aero

Lift-up the vehicle.

Clean the transmission exterior.

Drain the ATF completely.

Note. Tighten the ATF drain plug after draining the ATF. Replace the gasket with a new one.

Tightening torque

25 Nm (2.5 kgf-m, 18.1 ft-lb)

Scheme 169

1. Oil pan
2. Drain plug (ATF)
3. Differential oil drain plug

Remove the oil pan.

Remove and clean the magnet.

Remove the old gasket on the oil pan and transmission case completely.

Disconnect each solenoid connector and remove ATF temperature sensor from control valve.

Scheme 170

1. Lock-up duty solenoid (Blue)
2. Low clutch timing solenoid (Gray)
3. Line pressure duty solenoid (Red)
4. Shift solenoid 2 (Yellow)
5. Shift solenoid 1 (Green)
6. 2-4 brake timing solenoid (Black)
7. 2-4 brake duty solenoid (Red)
8. ATF temperature sensor
9. Transfer duty solenoid (Brown)
10. Transmission ground

Remove the control valve body.

Note. When removing the control valve body, be careful not to interfere with transfer duty solenoid wiring.

Scheme 171

Saab 9-2X 2.5i Linear

Set the vehicle on a lift.

Disconnect the ground cable from battery.

Lift-up the vehicle.

Clean the transmission exterior.

Remove the drain plug and gasket, and then drain ATF.

Scheme 172

Replace the gasket with a new one, and then tighten the drain plug.

Tightening torque

25 Nm (2.5 kgf-m, 18.1 ft-lb)

Remove the oil pan.

Scheme 173

Remove the magnet.

Scheme 174

Clean the magnet.

Remove the liquid gasket completely from oil pan and transmission case.

Remove the control valve connector.

Scheme 175

Remove the oil cooler pipe.

Scheme 176

Remove the control valve body.

Note. Replace the control valve body as assembly, because the control valve body can not be disassembled.

Scheme 177

Saab 9-2X 2.0T Aero

Set the range select lever in "N" range.

Install the control valve, ATF temperature sensor and ground connectors.

Tightening torque

8 Nm (0.8 kgf-m, 5.8 ft-lb)

Scheme 178

Bolt length mm (in)

1. 30 (1.18)
2. 55 (2.17)

Connect all connectors.

Scheme 179

1. Lock-up duty solenoid (Blue)
2. Low clutch timing solenoid (Gray)
3. Line pressure duty solenoid (Red)
4. Shift solenoid 2 (Yellow)
5. Shift solenoid 1 (Green)
6. 2-4 brake timing solenoid (Black)
7. 2-4 brake duty solenoid (Red)
8. Transfer duty solenoid (Brown)

Attach the magnet at specified position.

Scheme 180

Apply proper amount of liquid gasket to the entire oil pan mating surface.

Liquid gasket

THREE BOND 1217B (Part No. 32005004)

Scheme 181

Apply liquid gasket fully to three holes other than screw holes on transmission case.

Liquid gasket

THREE BOND 1217B (Part No. 32005004)

Scheme 182

Install the oil pan by equally tightening the bolts.

Tightening torque

5 Nm (0.5 kgf-m, 3.6 ft-lb)

Pour ATF from the oil charge pipe.

Recommended fluid

Dexron III

Fluid capacity

Fill the same amount of fluid drained from drain plug hole.

Check the level of ATF.

Saab 9-2X 2.5i Linear

Check the control valve body for dirt and dust.

Temporarily install the control valve body to transmission.

Install the oil cooler pipe.

Tightening torque

8 Nm (0.8 kgf-m, 5.8 ft-lb)

Scheme 183

Tighten the bolts evenly.

Tightening torque

8 Nm (0.8 kgf-m, 5.8 ft-lb)

Scheme 184

1. Transmission ground Bolt length mm (in) 35 (1.38) 30 (1.18)

Attach the magnet at specified position of oil pan.

Scheme 185

Apply proper amount of liquid gasket to the entire oil pan mating surface.

Liquid gasket

THREE BOND 1217B (Part No. 32005004)

Scheme 186

Apply liquid gasket fully to three holes other than screw holes on transmission case.

Liquid gasket

THREE BOND 1217B (Part No. 32005004)

Scheme 187

Install the oil pan with tightening bolts evenly.

Tightening torque

5 Nm (0.5 kgf-m, 3.6 ft-lb)

Pour ATF into the oil charge pipe.

Recommended fluid

Dexron III type automatic transmission fluid

Fluid capacity

Fill the same amount of fluid drained from drain plug hole.

Bleed the air from control valve.

Check the level of ATF.

Perform the advance operation of learning control. (Saab 9-2X 2.5i Linear)

Set the vehicle on a lift.

Disconnect the ground cable from battery.

Remove intercooler.

Remove the pitching stopper.

Scheme 188

Remove center exhaust pipe.

Remove the rear exhaust pipe and muffler.

Raise the vehicle and drain the ATF.

Scheme 189

1. Oil pan
2. Drain plug (ATF)
3. Differential gear oil drain plug

Remove the heat shield cover. (If equipped)

Remove the propeller shaft.

Remove the transmission rear crossmember.

Support the transmission using a transmission jack and raise slightly.

Remove the bolts and nuts as shown in the figure.

Scheme 190

Remove the rear vehicle speed sensor.

Scheme 191

Remove the select cable nut.

Scheme 192

Move the gear select cable so that extension bolts can be removed.

Remove the bolts.

Remove the extension case.

Note. Use a container to catch oil flowing from extension.

Scheme 193

Disconnect the transfer duty solenoid connector.

Remove the transfer duty solenoid and transfer valve body.

Scheme 194

1. Transfer valve body
2. Transfer duty solenoid connector
3. Transfer duty solenoid

Install the transfer duty solenoid and transfer valve body.

Install the transfer duty solenoid and transfer valve body.

Tightening torque

T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)

Connect the transfer duty solenoid connector.

Scheme 195

1. Transfer valve body
2. Transfer duty solenoid connector
3. Transfer duty solenoid

Install a new gasket and the extension case to transmission case.

Tighten eleven bolts.

Tightening torque

25 Nm (2.5 kgf-m, 18.1 ft-lb)

Adjust the select cable.

Install the rear vehicle speed sensor.

Tightening torque

T: 7 Nm (0.7 kgf-m, 5.1 ft-lb)

Scheme 196

Install the transmission rear crossmember.

Tighten the bolts.

Tightening torque

T1: 35 Nm (3.6 kgf-m, 26 ft-lb)

T2: 70 Nm (7.1 kgf-m, 51 ft-lb)

Scheme 197

Remove the transmission jack.

Install the propeller shaft.

Install center and rear exhaust pipes, and muffler.

Connect the transmission harness connector.

Scheme 198

Install the pitching stopper.

Tightening torque

T1: 50 Nm (5.1 kgf-m, 37 ft-lb)

T2: 58 Nm (5.9 kgf-m, 43 ft-lb)

Scheme 199

Install intercooler. (Saab 9-2X 2.0T Aero)

Fill ATF up to the middle of the "COLD" side on level gauge by using the gauge hole.

Check the ATF level.

Note. The ATF filter is maintenance free.

Lift-up the vehicle.

Using ST, remove ATF filter.

ST 32005109 OIL FILTER WRENCH

Scheme 200

1. ATF filter

Get new ATF filter and apply a thin coat of ATF to the oil seal.

Install ATF filter. Turn it by hand, being careful not to damage oil seal.

Using ST, tighten ATF filter.

Calculate ATF filter torque specifications using the following formula.

T2 = L2/(L1 + L2) x T1

T1: 14 Nm (1.4 kgf-m, 10.1 ft-lb)

[Required torque setting]

T2: Tightening torque

L1: ST length 78 mm (3.07 in)

L2: Torque wrench length

Example

TIGHTENING TORQUE

Note. Align ST with torque wrench while tightening ATF filter.

ST 32005109 OIL FILTER WRENCH

Add ATF.

Inspect level of ATF.

Disconnect the ground cable from battery.

Scheme 201

Remove the lower cover and then disconnect the connector.

Remove the knee bolster.

Scheme 202

Disconnect the connectors from TCM.

Scheme 203

1. Transmission control module (TCM)
2. Brake pedal

Remove the TCM.

Install the TCM.

Tightening torque

7.5 Nm (0.76 kgf-m, 5.5 ft-lb)

Scheme 204

1. Transmission control module (TCM)
2. Brake pedal

Connect the connectors to TCM.

Install in the reverse order of removal.

Set the vehicle on a lift.

Remove battery and washer tank.

Lift-up the vehicle.

Remove the under cover.

Disconnect ATF cooler hose from radiator.

Note. Do not remove with a screwdriver or other pointed tools. When the hose is difficult to remove, wrap a shop cloth around the hose to protect it. Turn it with pliers, and then pull directly out with your hand.

Scheme 205

Disconnect ATF cooler hoses from pipes.

Note. Do not remove with a screwdriver or other pointed tools. When the hose is difficult to remove, wrap a shop cloth around the hose to protect it. Turn it with pliers, and then pull directly out with your hand.

Scheme 206

Remove ATF cooler pipe from frame.

Scheme 207

Remove the oil cooler inlet and outlet pipes.

Note. When removing outlet pipe, be careful not to lose ball and spring used with retaining screw.

Scheme 208

1. Inlet pipe
2. Outlet pipe

Install the oil cooler outlet and inlet pipes using a new aluminum washer.

Tightening torque

T1: 44 Nm (4.5 kgf-m, 32.5 ft -lb)

T2: 25 Nm (2.5 kgf-m, 18.1 ft -lb)

Scheme 209

Install ATF cooler pipe to frame.

Scheme 210

Connect ATF cooler hose to pipe transmission side.

Note. Install so that the hose is not folded over, excessively bent, or twisted. Be careful to insert the hose to the specified position.

Scheme 211

Connect ATF cooler hose to pipe of radiator side.

Note. Install so that the hose is not folded over, excessively bent, or twisted. Be careful to insert the hose to the specified position.

Scheme 212

Install the under cover.

Install battery and washer tank.

Fill ATF.

Note. Make sure there are no ATF leaks in joints between the transmission, radiator, pipes, and hoses.

Remove the air intake chamber. (Saab 9-2X 2.5i Linear)

Remove intercooler. (Saab 9-2X 2.0T Aero)

Disconnect the air breather hoses.

Scheme 213

Scheme 214

1. Saab 9-2X 2.5i Linear Air breather hose (Transmission case) Air breather hose (Oil pump housing)
2. Saab 9-2X 2.0T Aero Air breather hose (Transmission case) Air breather hose (Oil pump housing)

Install air breather hoses.

Scheme 215

Scheme 216

1. Saab 9-2X 2.5i Linear Air breather hose (Transmission case) Air breather hose (Oil pump housing)
2. Saab 9-2X 2.0T Aero Air breather hose (Transmission case) Air breather hose (Oil pump housing)

Install the air intake chamber. (Saab 9-2X 2.5i Linear)

Install intercooler. (Saab 9-2X 2.0T Aero)

Remove the air intake chamber. (Saab 9-2X 2.5i Linear)

Remove intercooler. (Saab 9-2X 2.0T Aero)

Remove the oil charge pipe, and remove the O-ring from the flange face.

Scheme 217

1. Oil level gauge
2. Oil charge pipe

Install the oil charge pipe with new O-ring.

Tightening torque

41 Nm (4.2 kgf-m, 30.4 ft -lb)

Scheme 218

1. Oil level gauge
2. Oil charge pipe

Install the air intake chamber. (Saab 9-2X 2.5i Linear)

Install intercooler. (Saab 9-2X 2.0T Aero)

Remove the transmission assembly from the vehicle.

Extract the torque converter clutch and oil pump shaft horizontally.

Note. Be careful not to scratch the bushing inside the oil pump shaft.

Scheme 219

Remove the input shaft.

Note. When the torque converter clutch assembly is removed, the input shaft will come out.

Scheme 220

Remove the clip from torque converter clutch.

Install the clip to torque converter clutch.

Install the oil pump shaft to the torque converter clutch, and then check the clip fits securely in its groove.

Insert the input shaft while turning lightly by hand.

Normal protrusion A

50 - 55 mm (1.97 - 2.17 in)

Scheme 221

Holding the torque converter clutch assembly by hand, carefully install it to the converter case. Be careful not to damage the bushing. Also avoid undue contact between the oil pump shaft bushing and stator shaft portion of the oil pump cover.

Rotate the shaft lightly by hand to engage the splines securely.

Dimension A

2.7 - 2.9 mm (0.106 - 0.114 in)

Scheme 222

1. Dimension A

Install the transmission assembly to vehicle.

Remove the transmission assembly.

Remove rear vehicle speed sensor.

Scheme 223

Scheme 224

1. MPT MODEL Rear vehicle speed sensor
2. VTD MODEL Rear vehicle speed sensor Separate transmission case and extension case sections.

Attach the selected thrust needle bearing to the end surface of reduction drive gear with vaseline.

Note. Install thrust needle bearing in the correct direction.

Install new gasket.

Install the extension case to the transmission case.

Tighten bolts to secure the case.

Tightening torque

25 Nm (2.5 kgf-m, 18.1 ft -lb)

Scheme 225

Install the rear vehicle speed sensor.

Tightening torque

7 Nm (0.7 kgf-m, 5.1 ft-lb)

Scheme 226

1. MPT MODEL Rear vehicle speed sensor
2. VTD MODEL Rear vehicle speed sensor

Install the transmission assembly.

Remove the transmission assembly from vehicle.

Remove the extension case and remove the transfer clutch.

Select the thrust needle bearing.

Install the transfer clutch assembly to the case.

Scheme 227

1. Transfer clutch
2. Extension case

Replace with new gasket, and tighten bolts to secure the case.

Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft -lb)

Scheme 228

Install the transmission assembly to vehicle.

Remove multi-plate clutch following the same instructions as for the extension case.

Install multi-plate clutch following the same instructions as for the extension case.

Remove transmission assembly.

Remove rear wheel speed sensor and separate extension case from transmission case.

Pull out the rear driveshaft from the center differential assembly.

Scheme 229

1. Rear driveshaft
2. Center differential carrier

Remove drive plate and driven plate.

Select the appropriate shim.

Install drive plate and driven plate.

Insert rear driveshaft into the center differential assembly.

Join transmission case and extension case. Install rear wheel speed sensor.

Install transmission assembly.

Remove the transmission assembly from the vehicle.

Remove rear vehicle speed sensor, and separate the transmission case and extension case.

Remove the reduction driven gear.

Using ST, extract the reduction drive gear.

ST1 32005145 PULLER SET

ST2 32005174 PULLER SET

Scheme 230

1. Reduction drive gear

Install the reduction drive gear assembly.

Note. Insert it fully into position until the bearing shoulder bottoms.

Scheme 231

1. Reduction drive gear

Install the reduction driven gear.

Combine the transmission case with the extension case, and install rear vehicle speed sensor.

Install the transmission assembly to the vehicle.

Remove the transmission assembly from vehicle.

Remove the rear wheel speed sensor, and separate the extension case from the transmission case.

Pull out the rear driveshaft.

Using the special tools, pull out the center differential carrier assembly.

ST1 32005145 PULLER SET

ST2 32005174 PULLER SET

Scheme 232

Pull out the shim(s) from transmission case.

Install the center differential assembly with the shim(s).

Note. Insert the center differential assembly and shim(s) completely into the bearing shoulder bottom.

Scheme 233

Insert the rear driveshaft.

Connect the transmission case and extension case, and install the rear wheel speed sensor.

Install the transmission assembly onto vehicle.

Remove the transmission assembly from the vehicle.

Remove rear vehicle speed sensor and separate transmission case and extension case sections.

Remove the reduction drive gear. (MPT model)

Remove the center differential carrier. (VTD model)

Remove the parking pawl, return spring and shaft.

Scheme 234

1. Return spring
2. Parking pawl

Install the parking pawl, shaft and return spring.

Scheme 235

1. Return spring
2. Parking pawl

Install the reduction drive gear.

Install the center differential carrier. (VTD model)

Install the rear vehicle speed sensor and extension case.

Install the transmission assembly to the vehicle.

Remove the transmission assembly from the vehicle.

Extract the torque converter clutch assembly.

Remove the input shaft.

Scheme 236

Lift-up lever behind the connector and disconnect it from stay.

Disconnect inhibitor switch connector from stay.

Scheme 237

1. Transmission harness
2. Inhibitor switch harness

Remove the oil charge pipe.

Remove the oil cooler inlet and outlet pipes.

Lightly tapping the converter case with plastic hammer, separate the transmission case and converter case.

Note. Be careful not to damage the oil seal and bushing inside the converter case by the oil pump cover. Be careful not to lose the rubber seal.

Scheme 238

Remove the seal pipe if it is attached. (Reusing is not allowed.)

Scheme 239

1. Seal pipe

Remove the differential assembly.

Remove the oil seal from converter case.

Check the appearance of each component and clean.

Force-fit the oil seal to the converter case with ST.

ST 32005058 DRIFT

Scheme 240

Install the differential assembly to the case.

Install the left and right side retainers.

Install the new seal pipe to the converter case.

Scheme 241

1. Seal pipe

Install the rubber seal to the converter case.

Scheme 242

1. Rubber seal

Apply proper amount of liquid gasket to the entire converter case mating surface.

Liquid gasket

THREE BOND 1215 (Part No. 32005013)

Scheme 243

1. THREE BOND 1215
2. Rubber seal

Install the converter case assembly without damaging bush and oil seal and secure with six bolts and four nuts.

Tightening torque

41 Nm (4.2 kgf-m, 30.4 ft-lb)

Scheme 244

Insert inhibitor switch and transmission connector into stay.

Install air breather hose.

Install the oil cooler pipes.

Install the oil charge pipe with O-ring.

Insert the input shaft while turning lightly by hand and verify the protrusion amount.

Normal protrusion A

50 - 55 mm (1.97 - 2.17 in)

Scheme 245

Install the torque converter clutch assembly.

Install the transmission assembly to the vehicle.

Remove the transmission assembly from the vehicle.

Extract the torque converter clutch assembly.

Remove the input shaft.

Scheme 246

Lift-up lever behind the transmission harness connector and disconnect it from stay.

Disconnect inhibitor switch connector from stay.

Remove the oil charge pipe.

Remove the oil cooler inlet and outlet pipes.

Separation of converter case and transmission case sections

Separate transmission case and extension case sections.

Remove the reduction drive gear. (MPT model)

Remove the center differential carrier. (VTD model)

Remove the reduction driven gear.

Loosen the oil pump housing mounting bolts.

Scheme 247

Place two wooden blocks on the workbench, and stand the transmission case with its rear end facing down.

Note. Be careful not to scratch the rear mating surface of the transmission case. Note that the parking rod and drive pinion protrude from the mating surface.

Scheme 248

Remove the oil pump housing and adjusting thrust washer.

Scheme 249

1. Oil pump housing

Secure the oil pump housing with two nuts and a bolt.

Tightening torque

42 Nm (4.3 kgf-m, 31 ft-lb)

Scheme 250

1. Oil pump housing

Install the converter case assembly to the transmission case assembly.

Install reduction driven gear.

Install the reduction drive gear. (MPT model)

Install the center differential carrier. (VTD model)

Combine the extension case with the transmission case, and install vehicle speed sensor 1 (rear).

Insert inhibitor switch and transmission connector into stay.

Scheme 251

1. Transmission harness
2. Inhibitor switch harness

Install the oil cooler pipe.

Install the oil charge pipe with O-ring.

Insert the input shaft while turning lightly by hand and verify the protrusion amount.

Normal protrusion A

50 - 55 mm (1.97 - 2.17 in)

Scheme 252

Install the torque converter clutch assembly.

Install the transmission assembly to the vehicle.

Remove the transmission assembly from vehicle.

Extract the torque converter clutch assembly.

Remove the input shaft.

Scheme 253

Lift-up lever behind the transmission harness connector and disconnect it from stay.

Disconnect inhibitor switch connector from stay.

Disconnect the air breather hose.

Remove the oil charge pipe.

Remove the oil cooler inlet and outlet pipes.

Separation of converter case and transmission case sections

Separate transmission case and extension case sections.

Remove the reduction drive gear. (MPT model)

Remove the center differential carrier. (VTD model)

Remove the reduction driven gear.

Remove the drive pinion shaft mounting bolt and remove the drive shaft assembly from oil pump housing.

Scheme 254

Assemble the drive pinion assembly to the oil pump housing.

Note. Pay attention not to bend the shim. Pay attention not to press the pinion into housing bore.

Tightening torque

40 Nm (4.0 kgf-m, 30 ft-lb)

Scheme 255

Combine the torque converter case with the transmission case.

Install the reduction driven gear.

Install the reduction drive gear. (MPT model)

Install the center differential carrier. (VTD model)

Combine the extension case with the transmission case, and install vehicle speed sensor 1 (rear).

Insert inhibitor switch and transmission connector into stay.

Install the oil cooler inlet and outlet pipes.

Install the oil charge pipe with O-ring.

Insert the input shaft while turning lightly by hand and verify the protrusion amount.

Normal protrusion A

50 - 55 mm (1.97 - 2.17 in)

Scheme 256

Install the torque converter clutch assembly.

Install the transmission assembly to vehicle.

Remove the transmission assembly from the vehicle.

Extract the torque converter clutch assembly.

Remove the input shaft.

Scheme 257

Lift-up lever behind the transmission harness connector and disconnect it from stay.

Disconnect inhibitor switch from stay.

Remove the oil charge pipe.

Remove the oil cooler inlet and outlet pipes.

Separation of converter case and transmission case.

Remove the seal pipe.

Remove the differential side retainer with ST.

Note. Hold the differential case assembly by hand to avoid damaging retainer mounting hole of the converter case.

ST 32005023 WRENCH ASSY

Remove the differential assembly without damaging installation part of retainer.

Install the differential assembly to the case, paying special attention not to damage the inside of the case (particularly, the differential side retainer contact surface).

Scheme 258

1. Differential assembly

Install the O-rings from left and right side retainer.

Using ST, install the side retainers.

ST 32005023 WRENCH ASSY

Adjust the front differential backlash.

Install the lock plate.

Tightening torque

25 Nm (2.5 kgf-m, 18.1 ft-lb)

Scheme 259

1. Lock plate

Install the new seal pipe to the converter case.

Scheme 260

1. Seal pipe

Install the converter case to transmission case.

Insert inhibitor switch and transmission connector into stay.

Scheme 261

1. Transmission harness
2. Inhibitor switch harness

Install oil cooler pipes.

Install the oil charge pipe with O-ring

Insert the input shaft while turning lightly by hand and verify the protrusion amount.

Normal protrusion A

50 - 55 mm (1.97 - 2.17 in)

Scheme 262

Install the torque converter clutch assembly.

Install the transmission assembly to the vehicle.

Remove the transmission assembly from the vehicle.

Extract the torque converter clutch assembly.

Remove the input shaft.

Scheme 263

Lift-up lever behind the transmission harness connector and disconnect it from stay.

Disconnect inhibitor switch connector from stay.

Disconnect the air breather hose.

Remove the oil charge pipe.

Remove the oil cooler inlet and outlet pipes.

Separation of converter case and transmission case.

Remove the oil pump housing.

Take out the high clutch, thrust needle bearing and reverse clutch assembly.

Scheme 264

1. High clutch and reverse clutch assembly
2. Thrust needle bearing

Take out the high clutch hub and the thrust bearing.

Scheme 265

1. High clutch hub
2. Thrust needle bearing

Take out the front sun gear and the thrust bearing.

Scheme 266

1. Front sun gear
2. Thrust needle bearing

Pull out leaf spring without folding.

Note. Remove it while pressing down on lower leaf spring.

Scheme 267

1. Leaf spring
2. Retaining plate

Remove snap ring and thrust needle bearing.

Scheme 268

1. Snap ring
2. Thrust needle bearing

Take out retaining plate, drive plate and driven plate of 2-4 brake.

Scheme 269

Take out the thrust needle bearing, planetary gear assembly and the low clutch assembly.

Scheme 270

Remove 2-4 brake seal.

Scheme 271

Remove snap ring.

Scheme 272

1. Snap ring
2. 2-4 brake piston

Take out 2 -4 brake return spring.

Scheme 273

Remove the 2-4 brake piston and piston retainer without damaging.

Scheme 274

1. 2-4 brake piston
2. 2-4 brake piston retainer

Pull out the leaf spring without folding.

Scheme 275

1. Leaf spring

Remove snap ring.

Scheme 276

1. Snap ring

Take out retaining plate, drive plate, driven plate and dish plate.

Scheme 277

Turn the transmission case upside down, and then take out the socket bolts while holding the one-way clutch inner race with hand.

Scheme 278

Take out the spring retainer.

Scheme 279

Take out the return spring.

Scheme 280

Apply compressed air.

Scheme 281

Take out the low & reverse piston.

Scheme 282

Install the low & reverse piston without tilting.

Note. Be careful not to damage the lip seal.

Scheme 283

Install return spring.

Scheme 284

Install spring retainer.

Scheme 285

Install the one-way clutch inner race, spring retainer and return spring.

Tighten socket head bolts evenly from the rear side of the transmission case.

Tightening torque

25 Nm (2.5 kgf-m, 18.1 ft-lb)

Scheme 286

Place the front side of transmission body up.

Install thrust needle bearing.

Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.

Set the micro gauge to retaining plate, and read its scale. Make more than three measurements at even distance and take the average value.

Note. The value, which is read in the gauge at this time, is zero point.

Scale and record the weight "Z" of a flat board which will be put on plates.

Note. Use a stiff flat board which does not bend against load. Use a flat board of its weight less than 83 N (8.5 kgf, 18.7 lb).

Put the flat board on retaining plate.

Scheme 287

Using the following formula, calculate "N" indicated on the push/pull gauge.

N = 83 N (8.5 kgf, 18.7 lb) - Z

N: Value indicated on push/pull gauge

83 N (8.5 kgf, 18.7 lb): Load applied to clutch plate

Z: Flat board weight

Press the center of retaining plate applying force of N with push/pull gauge, and then measure and record the height A. Make more than three measurements at even distance and take the average value.

Note. If three points, measure the height every 120°. If four points, measure the height every 90°.

Scheme 288

1. Dish plate
2. Driven plate
3. Drive plate
4. Retaining plate

Installation of the low & reverse brake

Install the dish plate, driven plate and retaining plate, and then secure them with snap ring.

Note. Pay attention to the orientation of dish plate.

Scheme 289

1. Snap ring

Apply compressed air intermittently to check for operation.

Scheme 290

Place the same thickness of shim on both sides to prevent the plate from tilting, and then measure and record the clearance B.

Note. Do not press the shim downward with excessive force, or else the waveform of drive plates will be broken down.

Scheme 291

Piston stroke calculation

Select the retaining plate within the specification by calculating with A and B dimensions which have been recorded before. If the calculated value exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.

T = A + B

T: Piston stroke

1. A: Collapse amount of drive plate
2. B: Clearance between retaining plate and snap ring

Saab 9-2X 2.5i Linear

Initial standard

2.15 - 2.65 mm (0.073 - 0.093 in)

Limit thickness

2.95 mm (0.104 in)

Saab 9-2X 2.0T Aero

Initial standard

2.70 - 3.20 mm (0.106 - 0.126 in)

Limit thickness

3.90 mm (0.154 in)

THICKNESS REFERENCE

Install the low & reverse brake leaf spring.

Scheme 292

1. Leaf spring

Install the 2-4 brake piston and 2-4 brake retainer by aligning hole of 2-4 brake retainer and hole of transmission case.

Scheme 293

1. 2-4 brake piston
2. 2-4 brake piston retainer

Install 2-4 brake piston return spring to transmission case.

Scheme 294

Position snap ring in transmission. Using ST, press the snap ring into place.

ST 32005113 COMPRESSOR

Scheme 295

Install planetary gear and low clutch assembly to transmission case.

Install carefully while rotating the low clutch and planetary gear assembly slowly paying special attention not to damage the seal ring.

Scheme 296

Selection of 2 -4 brake retaining plate (Saab 9-2X 2.0T Aero)

Install pressure plate, drive plate, driven plate, retaining plate and snap ring.

Scheme 297

Install a new 2-4 brake oil seal to transmission case.

Scheme 298

After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of the brake.

Scheme 299

Check the clearance between the retaining plate and the snap ring.

Note. Select a retaining plate with a suitable value from the following table, so that the clearance becomes the standard value. If it exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.

Initial standard

0.8 - 1.2 mm (0.031 - 0.047 in)

Limit thickness

1.5 mm (0.059 in)

Scheme 300

THICKNESS REFERENCE

Selection of 2 -4 brake retaining plate (Saab 9-2X 2.5i Linear)

Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.

Set the micro gauge to clutch, and read its scale.

Note. The value, which is read in the gauge at this time, is zero point.

Scale and record the weight "Z" of a flat board which will be put on plates.

Note. Use a stiff flat board which does not bend against load. Use a flat board of its weight less than 100 N (10.2 kgf, 22.5 lb).

Put the flat board on retaining plate.

Scheme 301

Using the following formula, calculate "N" indicated on the push/pull gauge.

N = 100 N (10.2 kgf, 22.5 lb) - Z

N: Value indicated on push/pull gauge

100 N (10.2 kgf, 22.5 lb): Load applied to clutch plate

Z: Flat board weight

Press the center of retaining plate applying force of N with push/pull gauge, and then measure and record the height A. Make more than three measurements at even distance and take the average value.

Note. If three points, measure the height every 120°. If four points, measure the height every 90°.

Scheme 302

1. Driven plate
2. Drive plate
3. Retaining plate

Install the pressure plate, drive plate, driven plate, retaining plate and snap ring.

Scheme 303

Install a new 2-4 brake oil seal to transmission case.

Scheme 304

After all 2-4 brake component parts have been installed, blow air intermittently and confirm the operation of brake.

Scheme 305

Measure and record the clearance B between the retaining plate and snap ring.

Scheme 306

Piston stroke calculation

Select the retaining plate within the specification by calculating with A and B dimensions which have been recorded before. If the calculated value exceeds the usage limit, replace the drive plate with a new one and adjust it within the specitication.

T = A + B

T: Piston stroke

A: Collapse amount of drive plate

B: Clearance between retaining plate and snap ring

Initial standard

1.7 - 2.1 mm (0.067 - 0.083 in)

Limit thickness

2.3 mm (0.091 in)

THICKNESS REFERENCE

Be careful not to mistake the location of the leaf spring to be inserted.

Scheme 307

1. Leaf spring
2. Retaining plate

Install thrust needle bearing in the correct direction.

Scheme 308

1. Snap ring
2. Thrust needle bearing
3. Upside
4. Downside
5. Outside

Install front sun gear and thrust needle bearing.

Scheme 309

1. Front sun gear
2. Thrust needle bearing
3. Clutch hub side
4. Front sun gear side
5. Outside

Install the high clutch hub.

Attach the thrust needle bearing to the hub with vaseline and install the hub by correctly engaging the splines of the front planetary carrier.

Install the thrust needle bearing in proper direction.

Scheme 310

1. High clutch hub
2. Thrust needle bearing
3. Upside
4. Downside
5. Outside

Install the high clutch assembly.

Scheme 311

1. High clutch and reverse clutch ASSY

Adjust total end play.

Install the thrust needle bearing in proper direction.

Scheme 312

1. High clutch and reverse clutch assembly
2. Thrust needle bearing
3. Upside
4. Downside
5. Outside

Install the oil pump housing assembly.

Install the converter case assembly to the transmission case assembly.

Insert inhibitor switch and transmission connector into stay.

Install air breather hose.

Scheme 313

1. Transmission harness
2. Inhibitor switch harness

Install oil cooler pipes.

Install the oil charge pipe with O-ring.

Insert the input shaft while turning lightly by hand. At this time, not to damage the bushing.

Normal protrusion A

50 - 55 mm (1.97 - 2.17 in)

Scheme 314

Install the torque converter clutch assembly.

Install the transmission assembly to the vehicle.

Remove the transmission assembly from the vehicle.

Extract the torque converter clutch assembly.

Remove the input shaft.

Lift-up lever behind the transmission harness connector and disconnect it from stay.

Disconnect the air breather hoses.

Disconnect inhibitor switch connector from stay.

Wrap vinyl tape around the nipple attached to the air breather hose.

Remove pitching stopper bracket.

Remove the inhibitor switch.

Scheme 315

Remove control valve body assembly.

Pull off the straight pin of manual plate.

Scheme 316

Remove bolts securing select lever, then remove select lever, manual plate and parking rod.

Note. Be careful not to damage the lips of the press-fitted oil seal in the case.

Scheme 317

1. Bolt
2. Range select lever
3. Manual plate
4. Parking rod

Remove the detention spring.

Scheme 318

Install detention spring to transmission case.

Tightening torque

6 Nm (0.6 kgf-m, 4.3 ft-lb)

Scheme 319

Insert range select lever, and tighten bolt.

Tightening torque

6 Nm (0.6 kgf-m, 4.3 ft-lb)

Scheme 320

Install the manual plate and parking rod.

Scheme 321

1. Bolt
2. Range select lever
3. Manual plate
4. Parking rod

Insert spring pin to manual plate.

Scheme 322

Install control valve assembly and oil pan.

Turn over the transmission case to its original position.

Install pitching stopper bracket.

Tightening torque

41 Nm (4.2 kgf-m, 30.4 ft-lb)

Install inhibitor switch and adjust the inhibitor switch.

Insert inhibitor switch and transmission connector into stay.

Scheme 323

1. Transmission harness
2. Inhibitor switch harness

Install air breather hose.

Insert the input shaft while turning lightly by hand and verify the protrusion amount.

Normal protrusion A

50 - 55 mm (1.97 - 2.17 in)

Scheme 324

Install the torque converter clutch assembly.

Install the transmission assembly to the vehicle.