Automatic Transmission: Removal & Installation Saab 9-5 I рестайлинг 2

To remove

Scheme 175

1. Remove the «VALVE HOUSING COVER»(ref-274822-S35266602192007122400000)
2. Unplug the solenoids and temperature sensor.
3. Slacken the bolts with 10 mm heads securing the valve housing. NOTE: Start with the two retaining bolts at the bottom left that secure the cover to the oil duct and save the two top bolts until last. The bolts are different lengths. IMPORTANT: The passages are filled with transmission fluid.
4. Carefully detach the manual valve from the selector lever out of the retaining eye and carefully lift out the valve housing. NOTE: Make sure that the two O-rings fitted inside the valve housing do not fall out.

Scheme 176

1. Remove the «VALVE HOUSING COVER»(ref-274822-S35266602192007122400000) .
2. Unplug the relevant solenoid's connector.
3. Remove the solenoid's retaining bolt.
4. Prise the solenoid loose, using a screwdriver.

Scheme 177

1. Position the solenoid and tighten the bolt. Tightening torque: 7 Nm (5 lbf ft).
2. Plug in the solenoid's connector.
3. Fit the «VALVE HOUSING COVER»(ref-274822-S35266602192007122400000) .

Scheme 178

Scheme 179

1. Raise the car and remove the wheel.
2. Remove the drive shaft from the gearbox using «REMOVAL TOOL, DRIVE SHAFTS 87 92 616»(ref-274822-S12332302052007122400000) .
3. Remove the clips for the brake hose and the mountings for the ABS lead.
4. Remove the bolt securing the ball joint to the steering swivel member. Prise loose and lower the suspension arm. Fixate it in position with a wooden block placed between the suspension arm and anti-roll bar. IMPORTANT: Place a vessel under the transmission casing to avoid oil spill on the floor.
5. Turn the wheel to the right to make it easier to remove the drive shaft. Take hold of the MacPherson strut and pull. The drive shaft will follow. Then lower it in front of the suspension arm.
6. Remove the seal with «PULLER, DRIVE SHAFT SEAL 87 92 350»(ref-274822-S31453471052007122400000) and «PULLER, BASIC TOOL, DRIVE SHAFT SEAL 87 91 683»(ref-274822-S18146388562007122400000) .

Scheme 180

Scheme 181

1. Tap on the new seal with «DRIFT 83 90 122»(ref-274822-S33803387802007122400000) . Lubricate the seal with transmission fluid
2. Fit «PROTECTIVE COLLAR 83 95 162»(ref-274822-S13454779072007122400000) in the sealing ring.
3. Make sure that the drive shaft is clean and then align it with the tool. IMPORTANT: Insert all but approx. 20 mm of the drive shaft into the transmission and withdraw the tool before the shaft's sealing surface reaches the shaft seal.
4. Press in the rest of the shaft until the circlip clicks in.
5. Fit the ball joint to the steering swivel member and tighten. Tightening torque: 65 Nm (48 lbf ft)
6. Fasten the brake hose to the bracket for the steering swivel member and fit the locking clips and the two ABS mountings.
7. «FIT THE WHEEL»(ref-274828-S14401379102007122400000) .
8. Fill with transmission fluid to the correct level. Refer to «WEIGHT, FLUID CAPACITY AND GRADE OF FLUID»(ref-274822-S07228452902007122400000)

Scheme 182

1. Remove the intermediate shaft, see «INTERMEDIATE SHAFT 4-CYL»(ref-274854-S12687989162007122400000)
2. Remove the seal using a large screwdriver.

Scheme 183

1. Lubricate and fit the new seals with tools «83 90 122»(ref-274822-S33803387802007122400000) and «83 90 148»(ref-274822-S23644764672007122400000) .
2. Fit the intermediate shaft, see «INTERMEDIATE SHAFT 4-CYL»(ref-274854-S12687989162007122400000) .

Scheme 184

Scheme 185

1. Remove the battery cover and the battery.
2. Remove the MAXI fuse board from the battery tray and place it to one side. Remove the battery tray.
3. Clean round the place where the fluid filler pipe enters the transmission.
4. Remove the fluid filler pipe.
5. Move the selector lever to position L and undo the nut on the lever.
6. Remove the lever.
7. Remove the gear selector position sensor's retaining bolts.
8. Bend out the locking plate and remove the nut from the selector lever position sensor.
9. Unplug the connector and lift the sensor off the shaft.

Scheme 186

Scheme 187

Scheme 188

Scheme 189

1. Fit the sensor to the shaft and plug in the connector.
2. Fit the bracket for the cable entry. Tighten the bolts for the selector lever position sensor first (important). Then tighten the nut on the selector lever position sensor and bend up the locking plate. Tightening torque, bolts 25 Nm (18 lbf ft) Tightening torque, nut 8 Nm (6 lbf ft)
3. Engage neutral, fit «ADJUSTMENT TOOL, GEAR SELECTOR POSITION SENSOR 87 92 467»(ref-274822-S09725652122007122400000) . Undo the selector lever position sensor bolts and adjust the sensor so that the line is visible in the centre of the slot in the adjustment tool. Tighten the bolts. Tightening torque 25 Nm (18 lbf ft)
4. Remove the adjustment tool.
5. Clean and lubricate the fluid filler pipe's O-ring with petroleum jelly (Vaseline).
6. Refit the fluid filler pipe. Tightening torque 22 Nm (16 lbf ft)
7. Fit the selector lever cable lever. Before tightening the nut, move the selector lever to position P (to relieve the tension in the wire). Tightening torque 20 Nm (15 lbf ft)
8. Fit the battery tray, battery and MAXI fuse board.
9. Fit the battery cover.
10. Check that the engine starts when the selector lever is in positions P and N. The engine must not start in positions R, M, and L. The reversing light shall only be illuminated in position R.
11. Set the right time on the clock. IMPORTANT: On cars with a shift-lock function, incorrect adjustment of the gear selector position sensor could result in disablement of this function (SHIFT-LOCK).

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

1. Remove the battery cover and the battery.
2. Remove the MAXI fuse board and place it to one side. Remove the battery tray.
3. Clean round the fluid filler pipe where it enters the transmission.
4. Remove the fluid filler pipe's nut and remove the pipe.
5. Move the selector lever to position L and undo the nut on the lever.
6. Remove the lever.
7. Engage neutral, fit «ADJUSTMENT TOOL, GEAR SELECTOR POSITION SENSOR 87 92 467»(ref-274822-S09725652122007122400000) .
8. Undo the bolts securing the gear selector position sensor and adjust it until the line is visible in the centre of the slot in the adjustment tool. Tighten the bolts. Tightening torque 25 Nm (18 lbf ft)
9. Remove the adjustment tool.
10. Clean and lubricate the fluid filler pipe's O-ring with petroleum jelly (Vaseline) and fit the fluid filler pipe. Tightening torque 22 Nm (16 lbf ft)
11. Fit the selector lever cable lever. Before tightening the nut, move the selector lever to position P (to relieve the cable of tension). Tightening torque 20 Nm (15 lbf ft)
12. Fit the battery tray and MAXI fuse board.
13. Fit the battery and battery cover.
14. Check that the engine starts with the selector lever in positions P and N. The engine must not start in positions R, D, 4, 3 or L. The reversing light must only come on in position R.
15. Set the right time on the clock. IMPORTANT: On cars with the shift-lock function a faulty adjustment of the gear position sensor means that the shift-lock function can be deactivated.

Scheme 195

Scheme 196

1. Remove the battery cover and the battery.
2. Remove the MAXI fuse holder from the battery tray and place it to one side. Remove the battery tray.
3. Undo the battery cable bracket.
4. Clean the area round the sensor. Remove the sensor's retaining bolt.
5. Remove the sensor.
6. Unplug the connector.

Scheme 197

Scheme 198

1. Plug in the sensor's connector.
2. Fit the sensor in place.
3. Tighten the sensor's retaining bolt. Tightening torque: 6 Nm (4.5 lbf ft)
4. Fit the battery cable bracket.
5. Fit the battery tray, MAXI fuse board, battery and battery cover.
6. Set the right time on the clock.

Scheme 199

Scheme 200

1. Remove the battery cover and the battery.
2. Remove the MAXI fuse board and place it to one side. Remove the battery tray.
3. Disconnect the electrical distribution unit and move it aside.
4. Clean the area round the sensor. Remove the retaining bolt and withdraw the sensor.
5. Unplug the sensor's connector.

Scheme 201

Scheme 202

1. Plug in the sensor's connector.
2. Fit the sensor in place and tighten the retaining bolt. Tightening torque: 6 Nm (4.5 lbf ft)
3. Fit the electrical distribution unit.
4. Fit the battery tray and MAXI fuse board.
5. Fit the battery and battery cover.
6. Set the right time on the clock.

Scheme 203

Scheme 204

Scheme 205

1. Raise the car.
2. Place an oil pan under the transmission to collect fluid spill.
3. Remove the banjo screw for the delivery line and plug the hole. Use e.g. plug, part no. 91 32 929, and seal, part no. 91 32 937.
4. Lower the car to the floor.
5. Remove the upper banjo bolt from the radiator.
6. Remove the pipes' bracket from the fan cowling.
7. Remove the screws securing the fan cowling to the radiator.
8. Raise the fan cowling slightly and remove the delivery pipe.