Differentials: Removal & Installation Saab 9-2X I

REPLACEMENT

Jack-up the vehicle and support it with sturdy racks.

Remove the oil drain plug and filler plug, and drain the gear oil.

Scheme 7

1. Filler plug
2. Drain plug

Tighten the oil drain plug.

Note. Apply fluid packing to the drain plug.

Fluid packing

THREE BOND 1105 (Part No. 32005014) or equivalent

Tightening torque

49 Nm (5.0 kgf-m, 36.2 ft -lb)

Fill the differential carrier with gear oil to the upper plug level.

Note. Carefully refill oil while watching the level. Excess or insufficient oil must be avoided.

Recommended oil

GL-5 (75W-90) or equivalent

Oil capacity

0.8 liters (0.8 US qt, 0.7 Imp qt)

Scheme 8

1. Filler plug
2. Drain plug

Install the filler plug.

Note. Apply fluid packing to the filler plug.

Fluid packing

THREE BOND 1105 (Part No. 32005014) or equivalent

Tightening torque

49 Nm (5.0 kgf-m, 36.2 ft -lb)

REMOVAL

Set the vehicle on a lift.

Disconnect the ground cable from battery.

Move the select lever or gear shift lever to "N".

Release the parking brake.

Loosen the wheel nuts.

Jack-up the vehicle and support it with sturdy racks.

Remove the wheels.

Remove the rear exhaust pipe and muffler.

Saab 9-2X 2.5i Linear

and

Saab 9-2X 2.0T Aero

and

Remove the heat shield cover. (If equipped)

Remove the front cover of rear differential mount.

Scheme 9

Remove the propeller shaft.

Remove the rear differential protector. (If equipped)

Remove the clamps and bracket of parking brake cable.

Scheme 10

Remove the DOJ of rear drive shaft from rear differential using ST.

ST 32005038 DRIVE SHAFT REMOVER

Scheme 11

1. Bolt

Secure the rear drive shaft to rear crossmember using wire.

Scheme 12

Remove the lower bracket.

Scheme 13

1. Lower bracket

Support the rear differential with transmission jack.

Scheme 14

Remove the self-locking nuts and bolts.

Scheme 15

Remove the bolts which secure the rear differential front member to body.

Loosen the bolt A first, then remove the bolts B.

Note. Support the front member with use of a helper to prevent it from dropping.

Scheme 16

1. Bolt A
2. Bolt B

Remove the bolt A.

While slowly lowering the transmission jack, move the rear differential forward and remove front member and rear differential from vehicle.

Scheme 17

Remove the rear differential from vehicle.

Scheme 18

INSTALLATION

Install the air breather cap tapping with a plastic hammer.

Note. Be sure to install a new air breather cap.

Position the front member on body by passing it under the parking brake cable and securing to rear differential.

Note. When installing the rear differential front member, do not confuse the installation sequence of the upper and lower stoppers.

Install the DOJ of drive shaft into rear differential.

ST 32005037 SIDE OIL SEAL PROTECTOR

Scheme 19

Installing procedure hereafter is in the reverse order of removal.

After installation, fill the differential carrier with gear oil to the filler plug level.

Set the vehicle on a lift.

Disconnect the ground cable from battery.

Move the select lever or gear shift lever to "N".

Release the parking brake.

Remove the oil drain plug, and drain the gear oil.

Scheme 20

1. Filler plug
2. Drain plug

Install the oil drain plug.

Note. Apply liquid gasket to the drain plug.

Liquid gasket

THREE BOND 1105 (Part No.32005014) or equivalent.

Tightening torque

49 Nm (5.0 kgf-m, 36.2 ft -lb)

Jack-up the vehicle and support with sturdy racks.

Remove the rear exhaust pipe and muffler.

Remove the propeller shaft from body.

Remove the self-locking nut while holding the companion flange with ST.

ST 32005101 FLANGE WRENCH

Scheme 21

Remove the tank cover.

Scheme 22

Extract the companion flange using ST.

ST 32005080 PULLER ASSY

Scheme 23

Remove the oil seal using ST.

ST 32005071 PULLER ASSY

Scheme 24

Fit a new oil seal using ST.

ST 32005104 INSTALLER

Install the companion flange.

Scheme 25

Note. Use a plastic hammer to install the companion flange.

Tighten the self-locking nut within the specified torque range so that the preload of companion flange becomes the same as that before replacing oil seal.

ST 32005101 FLANGE WRENCH

Note. Use a new self-locking nut.

Tightening torque

181 Nm (18.5 kgf-m, 134 ft-lb)

Scheme 26

Hereafter, reassemble in the reverse order of disassembly.

Fill the differential carrier with gear oil to the bottom of filler plug hole after installing.

Disconnect the ground cable from battery.

Move the select lever or gear shift lever to "N".

Release the parking brake.

Loosen both wheel nuts.

Jack-up the vehicle and support it with rigid racks.

Remove the wheels.

Remove the rear exhaust pipe and muffler.

Saab 9-2X 2.5i Linear

and

Saab 9-2X 2.0T Aero

and

Remove the DOJ of rear drive shaft from rear differential.

Remove the ABS wheel speed sensor cable clamp and parking brake cable clamp from bracket.

Scheme 27

1. ABS wheel speed sensor cable clamp
2. Parking brake cable clamp

Remove the ABS wheel speed sensor cable clamp from trailing link.

Scheme 28

Remove the ABS wheel speed sensor cable clamp and parking brake cable guide from trailing link.

Scheme 29

1. Parking brake cable guide
2. ABS wheel speed sensor cable clamp

Remove the rear stabilizer link.

Scheme 30

Remove the bolts which secure trailing link to housing.

Scheme 31

Remove the bolts which secure the front and rear lateral link to rear housing.

Scheme 32

Remove the DOJ from the rear differential by using ST.

Note. When removing the DOJ from rear differential, fit ST to the bolts as shown in the figure so as not to damage the side bearing retainer.

ST 208099PA100 DRIVE SHAFT REMOVER

Scheme 33

1. Bolt

Suspend the rear drive shaft to the rear crossmember using wire.

Scheme 34

Remove the oil seal using ST.

ST 32005071 PULLER ASSY

Scheme 35

Drive in a new side oil seal using ST.

Note. Apply chassis grease between the oil seal lips.

ST 32005058 DRIFT

Scheme 36

Insert the DOJ into rear differential.

Install the ST to rear differential.

ST 32005037 SIDE OIL SEAL PROTECTOR

Scheme 37

Install the spline shaft until the spline portion is inside the side oil seal using ST.

ST 32005037 SIDE OIL SEAL PROTECTOR

Scheme 38

Remove the ST.

ST 32005037 SIDE OIL SEAL PROTECTOR

Hereafter, reassemble in the reverse order of disassembly.

Set the vehicle on a lift.

Disconnect the ground cable from battery.

Move the selector lever or gear shift lever to "N".

Release the parking brake.

Loosen the wheel nuts.

Jack-up the vehicle and support it with study racks.

Remove the wheels.

Remove the rear exhaust pipe and muffler.

Saab 9-2X 2.5i Linear

and

Saab 9-2X 2.0T Aero

and

Remove the rear differential front member.

Note. When removing the rear differential front member, work the removal procedure as rear differential.

Remove the differential rear member.

Position the front member on body by passing it under the parking brake cable and securing to rear differential.

Note. When installing the rear differential front member, do not confuse the installation sequence of the stopper.

Scheme 39

Insert the DOJ of rear drive shaft into rear differential.

Note. Before inserting, replace the differential side oil seal with a new one.

ST 32005037 SIDE OIL SEAL PROTECTOR

Scheme 40

Hereafter, install in the reverse order of removal.