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Home >> Saab >> 2001 >> 9-3 Base, 4D Hatchback, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission >> Adjustment-Replacement >> Gearcase and torque converter housing >> Notes

Gearcase and torque converter housing: Notes

IMPORTANT: It is very important to observe great cleanliness when working on the gearbox. Dirt particles can seriously damage the function and service life of the gearbox.
  1. Drain the oil from the gearbox before removing any parts. Remove the gearbox from the car. See AUTOMATIC GEARBOX ASSEMBLY . Fit the dipstick pipe.
    Fig 1: Illustration For Steps 1, 3 & 4
    G03504690Courtesy of SAAB-SCANIA OF AMERICA, INC.
  2. Plug the shaft hole. Clean the exterior of the gearcase. Use plug 91 32 929, and seals 91 32 937 and 87 92 244. Plug the breather pipe.
  3. Undo the connectors and remove the wiring harness.
  4. Remove the dipstick pipe. Remove the selector lever bracket.
  5. Fit holder 87 92 392 to the gearbox with an M8x25 flange bolt. Position the gearbox on stand 78 74 878.
    Fig 2: Illustration For Step 5
    G03504691Courtesy of SAAB-SCANIA OF AMERICA, INC.
    NOTE: During removal it is important that the work area is well organized with groups of associated parts to facilitate fitting.
  6. If there is an engine mounting on the gearbox, remove it.
    Fig 3: Illustration For Step 6
    G03504692Courtesy of SAAB-SCANIA OF AMERICA, INC.
  7. Pry out the lock washer on the nut of the gear selector position sensor, and loosen the nut slightly.
    Fig 4: Illustration For Steps 7-8
    G03504693Courtesy of SAAB-SCANIA OF AMERICA, INC.
  8. Remove the gear selector position sensor. (NOTE different cable lengths.)
  9. Unplug the connectors to the speed sensors and temperature sensor. Remove the speed sensors.
    Fig 5: Illustration For Step 9
    G03504694Courtesy of SAAB-SCANIA OF AMERICA, INC.
  10. Fit tool 87 92 681 or 87 91 766 to the torque converter. Remove holder 87 92 277 or 87 92 574. Remove the torque converter.
    Fig 6: Illustration For Step 10
    G03504695Courtesy of SAAB-SCANIA OF AMERICA, INC.
  11. Turn the gearbox 180° on the stand.
    Fig 7: Removing Cover Plate And Temperature Sensor
    G03504696Courtesy of SAAB-SCANIA OF AMERICA, INC.
  12. Remove the cover plate and temperature sensor.
    Fig 8: Illustration For Steps 12-13
    G03504697Courtesy of SAAB-SCANIA OF AMERICA, INC.
  13. Remove metal cover of the torque converter housing.
  14. Remove the bolts holding the valve housing cover and tap off the cover using a shatterproof plastic mallet.
    Fig 9: Illustration For Step 14
    G03504698Courtesy of SAAB-SCANIA OF AMERICA, INC.
    IMPORTANT: Take care that the sealing surfaces are not damaged.
  15. Disconnect the electrical connectors of the solenoids. Lift the casing of the system pressure solenoid slightly with a small screwdriver to release the catch. Unhook the cable. Pull the cable and grommet out of the gearcase. Place the holder to one side.
    Fig 10: Illustration For Steps 15-17
    G03504699Courtesy of SAAB-SCANIA OF AMERICA, INC.
  16. Remove the bolts of the valve housing (only bolts with 10 mm head). Keep the small cover safe.
  17. Unhook the piston rod of the manual valve from the valve control and remove the valve housing.
  18. Remove the two seals.
    Fig 11: Illustration For Step 18
    G03504700Courtesy of SAAB-SCANIA OF AMERICA, INC.
  19. Remove the bolts securing the oil pump to the gearcase.
    Fig 12: Illustration For Step 20
    G03504701Courtesy of SAAB-SCANIA OF AMERICA, INC.
  20. Pull the oil pump and brake unit B2 off from the gearcase using puller 87 92 699.
  21. Remove the brake hub and freewheel F1.
    Fig 13: Illustration For Step 21
    G03504702Courtesy of SAAB-SCANIA OF AMERICA, INC.
  22. Turn the gearbox 90° on the stand.
    Fig 14: Removing Torque Converter Housing
    G03504703Courtesy of SAAB-SCANIA OF AMERICA, INC.
  23. Remove the torque converter housing. Knock the housing loose using a plastic mallet. Remove the small seal.
    Fig 15: Illustration For Step 23
    G03504704Courtesy of SAAB-SCANIA OF AMERICA, INC.
  24. Lift out the differential unit.
    Fig 16: Illustration For Steps 23-26
    G03504705Courtesy of SAAB-SCANIA OF AMERICA, INC.
  25. Remove the oil strainer and cover panel.
  26. Remove the oil duct plate from the gearcase.
  27. Remove the twist spring and handbrake pawl pin.
    Fig 17: Illustration For Steps 27-29
    G03504706Courtesy of SAAB-SCANIA OF AMERICA, INC.
  28. Remove the handbrake lever and the gear selector position plate. Detension the catch spring.
  29. Remove the pin seal from the selector lever pin.
  30. Remove the handbrake lever bracket and the catch spring.
    Fig 18: Illustration For Steps 30-31
    G03504707Courtesy of SAAB-SCANIA OF AMERICA, INC.
  31. Remove the handbrake pawl and guide pin.
  32. Remove the bracket and twist spring.
    Fig 19: Illustration For Steps 30-31
    G03504708Courtesy of SAAB-SCANIA OF AMERICA, INC.
  33. Remove the cover with O-ring, piston and spring.
    Fig 20: Illustration For Step 33
    G03504709Courtesy of SAAB-SCANIA OF AMERICA, INC.
  34. Lift out the output shaft complete with thrust bearings and bearing races.
  35. Lift out clutch C3 and the bearing race. Keep the thrust bearing safe.
    Fig 21: Illustration For Steps 35-36
    G03504710Courtesy of SAAB-SCANIA OF AMERICA, INC.
  36. Lift the brake band of brake B4 out of the gearcase.
  37. Remove the circlip for freewheel F3 from the gearcase. Lift out F3. Keep the small retainer safe.
    Fig 22: Illustration For Step 37
    G03504711Courtesy of SAAB-SCANIA OF AMERICA, INC.
  38. Remove the oil sealing rings by pressing one side of the ring against the groove and removing the ring.
    Fig 23: Illustration For Step 38
    G03504712Courtesy of SAAB-SCANIA OF AMERICA, INC.
  39. Turn the gearbox 180°
    Fig 24: Removing Cover
    G03504713Courtesy of SAAB-SCANIA OF AMERICA, INC.
  40. Remove the circlip, cover, piston, spring and the two O-rings of the B4 brake piston. NOTE, take care, the spring can cause the cover and piston to fly off.
    Fig 25: Illustration For Step 40
    G03504714Courtesy of SAAB-SCANIA OF AMERICA, INC.
  41. Remove the bolts holding the end cover. Tap off the cover using a plastic mallet. Remove the four seals.
    Fig 26: Illustration For Step 41
    G03504715Courtesy of SAAB-SCANIA OF AMERICA, INC.
  42. Remove the pipe of the C3 solenoid. Use sliding hammer 83 90 270 and hook 87 92 384.
    Fig 27: Illustration For Steps 42-44
    G03504716Courtesy of SAAB-SCANIA OF AMERICA, INC.
  43. Remove the pipe bracket and remove the other pipe. Use sliding hammer 83 90 270 and hook 87 92 384.
  44. Remove the bearing and bearing race from the cover and the bearing race from the turbine shaft unit with clutch C1 and C2.
  45. Lift out the turbine shaft unit with clutch C1 and C2. Keep the thrust bearing and thrust bearing race safe.
    Fig 28: Illustration For Steps 45-46
    G03504717Courtesy of SAAB-SCANIA OF AMERICA, INC.
  46. Lift out sun gear of the planetary gear set and the thrust bearing. Keep the thrust bearing race safe.
  47. Remove the rear ring gear. Keep the thrust bearing and bearing race safe.
    Fig 29: Illustration For Steps 47-48
    G03504718Courtesy of SAAB-SCANIA OF AMERICA, INC.
  48. Lift out the planetary gear set and the large thrust bearing.
  49. Remove the circlip from freewheel F2 and brake B3 with a screwdriver. Lift out the ring gear with F2 and B3 which contains a plate assembly and flanges.
    Fig 30: Illustration For Steps 49-50
    G03504719Courtesy of SAAB-SCANIA OF AMERICA, INC.
  50. Keep the thrust bearing and bearing race safe.
  51. Remove the circlip from the spring package using a screwdriver. Lift out the spring package.
  52. If necessary, remove the accumulator of C1 from the end cover with spring and piston.
    Fig 31: Illustration For Step 52
    G03504720Courtesy of SAAB-SCANIA OF AMERICA, INC.
  53. Remove the plug by the end cover
  54. Carefully apply compressed air at a pressure of 4 bar through the oil duct for B3 (as illustrated) to remove the B3 piston. If the piston does not come out, assist removal with needle-nose pliers.
    Fig 32: Illustration For Step 54
    G03504721Courtesy of SAAB-SCANIA OF AMERICA, INC.
  55. Turn the gearbox 90°.
    Fig 33: Illustration For Step 56
    G03504722Courtesy of SAAB-SCANIA OF AMERICA, INC.
  56. Remove the circlip of the idler. Use circlip pliers 87 90 180 with tips 87 90 297 and a small screwdriver. Remove the idler.
  57. Turn the gearbox 90°
    Fig 34: Illustration For Step 58
    G03504723Courtesy of SAAB-SCANIA OF AMERICA, INC.
  58. Remove the drive shaft seal using a hammer and screwdriver.
  59. Fit pullers 87 92 707 and 87 92 715. Remove the bearing race from the gearcase by heating the gear case with a heat gun for about 5 minutes. Pull out the bearing race and keep the shims safe.
    Fig 35: Illustration For Step 59
    G03504724Courtesy of SAAB-SCANIA OF AMERICA, INC.
  60. Remove the brake band holder and the remaining plugs from the gearcase. (Do not mix up the plugs.)
    Fig 36: Illustration For Step 60
    G03504725Courtesy of SAAB-SCANIA OF AMERICA, INC.
  61. Remove the bolt and pipe clip from the torque converter housing.
    Fig 37: Illustration For Steps 61-63
    G03504726Courtesy of SAAB-SCANIA OF AMERICA, INC.
  62. Detach both ends of the pipe using sliding hammer 83 90 270 and hook 87 92 384. Remove the pipe. Be careful not to damage the pipe.
  63. Remove the oil duct plate, (three bolts). Remove the three magnets.
  64. Fit pullers 87 91 675 and 87 91 683. Heat the bearing seat for about 5 minutes with a heat gun and remove the roller bearing.
    Fig 38: Illustration For Step 64
    G03504727Courtesy of SAAB-SCANIA OF AMERICA, INC.
  65. Tap out the shaft seal.
    Fig 39: Illustration For Step 66
    G03504728Courtesy of SAAB-SCANIA OF AMERICA, INC.
  66. Remove the bearing race of the conical roller bearing in the torque converter housing by heating around the bearing seat with a heat gun for about 5 minutes. Pull out the bearing using pullers 87 92 707 and 87 92 715. Remove the washer (certain variants only). The bearing need only be removed if the torque converter housing or differential bearing is changed.
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