LEMON Manuals: Even more car manuals for everyone
Home >> Saab >> 2003 >> 9-3 Vector, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Gearbox >> Adjustment Replacement >> To fit

To fit

Fig 1: Illustration For Step 4
G03578465Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. Check that the selector lever in the car is in 3rd gear and that it is locked with 87 92 335 LOCKING PIN  for the gear lever housing. The locking pin ring should be down in the hole.
  2. Grease the spines of the primary shaft.
    IMPORTANT: Check that the two locating sleeves are on the engine. Lubricate the sleeves with a thin coating of anti-corrosion oil.
  3. If the slave cylinder is new or has been emptied of brake fluid, bleed the slave cylinder. See SLAVE CYLINDER .
  4. Fit 83 95 162 PROTECTIVE COLLAR, DRIVE SHAFTS  in the right-hand shaft seal in the gearbox to protect the seal when the gearbox is mounted.
    IMPORTANT: Always change the shaft seal in the gearbox. Lubricate with gearbox oil.
  5. Attach 87 92 608 HOLDER FOR SINGLE-COLUMN LIFT  . If the lifting tool's setting has been changed since removal, it must be adjusted so that its center is in line with the gearbox's center and mating surface.
    Fig 2: Fitting Gearbox With Lifting Tool Onto Pillar Jack
    G03578466Courtesy of SAAB-SCANIA OF AMERICA, INC.
  6. Fit the gearbox with lifting tool onto a pillar jack.
    WARNING: Take care not to tip the jack.
  7. Push in the gearbox until approx. 20 mm remain, remove 83 95 162 PROTECTIVE COLLAR, DRIVE SHAFTS  and then push in the gearbox completely. Turn the engine shaft, if needed, so that the gearbox can be fitted.
  8. Fit the rear engine mounting on the gearbox.
    Fig 3: Illustration For Step 8
    G03578467Courtesy of SAAB-SCANIA OF AMERICA, INC.
  9. Tighten the bottom bolts between the engine and gearbox.
    Fig 4: Illustration For Step 9, 13-14
    G03578468Courtesy of SAAB-SCANIA OF AMERICA, INC.

    Tightening torque 70 N.m (50 lbf ft). 

  10. Fit the left-hand engine mounting on the gearbox.

    Tightening torque 40 N.m (46 lbf ft) 

  11. Lift up the drive unit with a jack and tighten the left-hand engine mounting on the body.

    Tightening torque: 62 N.m (46 lbf ft) 

  12. Remove the lifting tool from the gearbox and remove the jack.
  13. Fit the ground leads to the gearbox.
  14. Put back the splash plate by the flywheel.
  15. Fit 83 95 162 PROTECTIVE COLLAR, DRIVE SHAFTS  in the left-hand shaft seal.
    Fig 5: Illustration For Step 15
    G03578469Courtesy of SAAB-SCANIA OF AMERICA, INC.
  16. Make sure the drive shaft is clean and then position it in the tool.
    IMPORTANT: Fit the driver in the gearbox until about 20 mm remains and withdraw the tool before the shaft's sealing surface reaches the shaft seal.
  17. Insert the shaft until the locking ring snaps in place.
  18. Carefully raise the subframe. Make sure the washers on the rear mountings are in place.
    Fig 6: Illustration For Steps 22-24
    G03578470Courtesy of SAAB-SCANIA OF AMERICA, INC.
  19. Adjust the subframe so that the screw holes correspond with the body.
  20. Tighten the four corner bolts on the subframe.

    Tightening torques 

    front 115 N.m (85 lbf ft) 

    rear 110 N.m (81 lbf ft) + 75. 

  21. Lower the lifting trolley and move it away.
  22. Tighten the remaining bolts on the subframe.

    Tightening torque: 190 N.m (141 lbf ft). 

  23. Tighten the nuts on the rear engine mounting.

    Tightening torque: 50 N.m (37 lbf ft) 

  24. Position the suspension arm end piece on both sides and tighten the nuts.

    Tightening torque: 75 N.m (55 lbf ft) 

  25. Refit the air shields and belt circuit cover in the right-hand wheel housing.
    Fig 7: Illustration For Step 25
    G03578471Courtesy of SAAB-SCANIA OF AMERICA, INC.
  26. Fit the front exhaust system and put back the clamps for the oxygen sensor cable.
    Fig 8: Illustration For Step 26
    G03578472Courtesy of SAAB-SCANIA OF AMERICA, INC.
  27. Fit the front wheels.

    Tightening torque: 110 N.m (81 lbf ft). 

    Lower the car to the floor.

  28. Remove the lifting beam and tighten the upper bolts between the engine and gearbox.
    Fig 9: Illustration For Steps 28-29
    G03578473Courtesy of SAAB-SCANIA OF AMERICA, INC.

    Tightening torque: 70 N.m (50 lbf ft) 

  29. Connect the oxygen sensor(s).
  30. Fit the positive cable mounting on the engine.
  31. Connect the lead to the reversing-light switch.
    Fig 10: Illustration For Steps 31-32
    G03578474Courtesy of SAAB-SCANIA OF AMERICA, INC.
  32. Connect the clutch deliver pipe to the gearbox and fir the locking clip.
  33. Remove 87 92 335 LOCKING PIN  from the gear lever housing, engage 4th gear and insert 87 92 632 LOCKING PIN  again.
    Fig 11: Illustration For Steps 33-35
    G03578475Courtesy of SAAB-SCANIA OF AMERICA, INC.
  34. Tighten the clamp on the selector rod.

    Tightening torque: 20 N.m (15 lbf ft) 

  35. Put back the gear lever gaiter.
  36. Take the locking pin out of the gearbox and put back the plastic plug.
    Fig 12: Illustration For Step 36
    G03578476Courtesy of SAAB-SCANIA OF AMERICA, INC.
  37. Remove the brake bracket from the clutch pedal. Attach a hose to the bleed nipple, open the nipple and let a little brake fluid run out. Tighten the nipple and test the clutch. If it does not work, bleed the clutch according to group 4, Clutch system, Adjustment and replacement, Bleeding of clutch hydraulic system in car. Check that there are no system leaks.
  38. Fit and connect the battery.
    Fig 13: Illustration For Step 39
    G03578477Courtesy of SAAB-SCANIA OF AMERICA, INC.
  39. Put back the cover over the engine or the resonator with hoses and the mass air flow sensor.
  40. Test drive the car and shift gears. Check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed as well as set the correct time on the clock and program any eventual radio code.
scientia non olet · About LEMON Manuals