Complete automatic transmission: Fitting

When fitting a new transmission, transfer the holder for the torque converter from the new transmission to the old one.

1. Turn the torque converter so that the bolt holes line up with the holes in the drive plate.

   Fit 87 92 574 HOLDER  to keep the torque converter in place while fitting.

   Fig 1: Identifying Holder

   Courtesy of SAAB-SCANIA OF AMERICA, INC.
2. Make sure the two guide sleeves are on the engine and apply anti-corrosion agent to the sleeves.

   Fit new drive shaft seals, lubricate them before fitting. Use SPECIAL TOOLS 87 92 657 Fitting drift, drive shaft seals.

3. Lift up the gearbox using an engine hoist and 87 92 442 LIFTING CABLE .
4. Fit Lifting SPECIAL TOOLS MKM-886 87 92 608 onto a pillar-type jack.
   Fig 2: Identifying Pillar-Type Jack

   Courtesy of SAAB-SCANIA OF AMERICA, INC.
5. Secure the tool to the transmission as described for removal.
   Fig 3: Illustration For Step 6

   Courtesy of SAAB-SCANIA OF AMERICA, INC.
   IMPORTANT: The pillar-type jack may tip over. Exercise care.
6. Fit PROTECTIVE COLLAR  in the right-hand shaft seal in the transmission to protect the seal when the transmission is being fitted. Lubricate the seal.
   Fig 4: Illustration For Step 8-10

   Courtesy of SAAB-SCANIA OF AMERICA, INC.
7. Place the transmission in position.
   IMPORTANT: Push the transmission into place until approx. 20 mm remains and then remove tool 83 95 162.
8. Tighten the bottom bolts between the engine and the transmission.

   Tightening torque 75 Nm (55 lbf ft) 

   V6:  Tighten the bolts between the oil pan and the transmission.

   Tightening torque 47 Nm (34 lbf ft) 

   Fig 5: Illustration For Step 12-14

   Courtesy of SAAB-SCANIA OF AMERICA, INC.
9. Remove the lifting beam from the transmission and move the jack out of the way. Refit the bolts in the gearbox.

   Tightening torque 24 Nm (18 lbf ft) 

10. Lower the car and fit the engine pad mounting on the gearbox.

    Tightening torque 60 Nm + 60° (44 lbf ft + 60°) 

    Raise the power train. Do not lift higher than necessary as this could make fitting to the subframe more difficult. Fit the bolts securing the engine pad to the body.

    NOTE: One of the rear bolts is shorter in order not to screw into the bottom of the hole. Ensure that the bolt holes are as close as possible to the center of the engine pad holes without tensioning the engine pad.

    Tightening torque, bolt with loose washer 63 Nm (46 lbf ft) 

    Tightening torque, bolt with captive washer 40 Nm + 30° (30 lbf ft + 30°) 

    Tightening torque, nut 84 Nm (62 lbf ft) 

11. Lower the engine assembly so that it is almost hanging free in the lifting beam.
12. Fit PROTECTIVE COLLAR  in the sealing ring. Lubricate the sealing ring.
    Fig 6: Illustration For Step 16-18

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
13. Make sure that the drive shaft is clean and then align it with the tool.
    IMPORTANT: Insert all but 20 mm of the drive shaft in the transmission and then withdraw the tool before the shaft's sealing surface reaches the shaft seal.
14. Push in the rest of the shaft until the circlip clicks in.
15. Raise the car.
16. Remove tool 87 92 574 that is keeping the torque converter in place and press it against the drive plate. Fit the plug.
    Fig 7: Illustration For Step 21-23

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
17. Apply threadlock, LOCTITE 242 part no SPECIAL TOOLS 74 96 268 to the bolts that secure the torque converter to the drive plate.
    NOTE: Use the original bolts and their washers. If excessively long bolts are fitted, the torque converter will be damaged.
18. Fit the 6 bolts without tightening them.
19. Rotate the engine using the drive belt pulley and tighten the bolts when they are all in place.

    Tightening torque 30 Nm (22 lbf ft) 

20. 4-cyl:  Fit the splash plate.

    V6:  Fit the plug.

21. Fit the oil cooler hoses. The hoses should be horizontal so that they do not chafe against the subframe. Use new seals greased with petroleum jelly.

    Tightening torque 27 Nm (20 lbf ft) 

    Fig 8: Illustration For Step 25-27

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
22. Fit the bracket for the torque arm on the transmission.
23. Connect the ground cable to the bracket and to the transmission.
24. Place the subframe on the lifting trolley and raise it slightly.
25. Fit the power steering delivery pipe's clamps.
    Fig 9: Illustration For Step 29-30

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
26. Lift up the subframe, while guiding it into place with the help of the pins on the holder. At the same time guide in:
    • The radiator core's studs
    • The AC pipes
    • Outer ball joints
27. Fit the bolts to the subframe and fit the rear support plates. Adjust the subframe so that the guide pins on the holder are aligned with the holes in the body before tightening the bolts.

    Tightening torque, subframe bolts 100 Nm + 45° (74 lbf ft + 45°) 

    Tightening torque, support plate bolts 60 Nm (44 lbf ft) 

    NOTE: The center bolts on the subframe must not be mixed up with the other bolts. The center bolts have smaller washers and 20 mm heads.
    NOTE: Make sure that the transmission's oil cooler hoses do not rest against the subframe.
28. Remove the lifting trolley.
29. Fit the bolts securing the outer ball joint to the steering knuckle housing.

    Tightening torque 50 Nm (37 lbf ft) 

    Fig 10: Illustration For Step 31-34

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
    IMPORTANT: Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.
30. Tighten the anti-roll bar link. If the wrench used to hold it is too wide to fit between the boot and the suspension strut, it must be ground narrower. Alternatively, hold the hexagonal pin with a socket.

    Tightening torque 84 Nm (62 lbf ft) 

    Tightening torque, nut with steel lock: 95 Nm (66 lbf ft) 

31. Fit the steering gear bolts and tighten them.

    Tightening torque 90 Nm (66 lbf ft) 

    Fig 11: Illustration For Step 35-37

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
32. Remove the strap round the radiator core.
33. 4-cyl:  Fit the engine oil cooler. Tighten the air filter housing.
34. Tighten the torque arm on the subframe

    Tightening torque 90 Nm + 90° (66 lbf ft + 90°) 

35. Loosely fit the rear engine pad by putting the bolts in place.
    Fig 12: Illustration For Step 43-44

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
36. Lower the vehicle and tighten the engine pad bolts from above.

    Tightening torque 24 Nm (18 lbf ft) 

37. Lift the vehicle and fit the engine bracket to the transmission.

    Tightening torque 60 Nm + 60° (44 lbf ft + 60°) 

38. Fit the front exhaust system.

    Tightening torque, 4-cyl 25 Nm (18.4 lbf ft) 

    Tightening torque, V6 to turbo 24 Nm (18 lbf ft) 

    Tightening torque, V6 to exhaust manifold 40 Nm (30 lbf ft) 

39. Run the wiring for the oxygen sensor into the engine bay.
40. Fit the covers.
41. Lower the car to the floor.
42. Remove the lifting beam.

    V6:  Remove the lifting tool and its mountings from the engine.

43. Connect the oxygen sensors
    Fig 13: Illustration For Step 45-49

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
44. Shake the unit to ensure there is no tension in the engine pads.

    Tighten the rear engine pad nuts.

    Tightening torque 45 Nm (33 lbf ft) 

45. Fit the bolts securing the transmission to the engine and tighten them.

    Tightening torque 70 Nm (52 lbf ft) 

    V6:  Fit the cable duct to the engine and gearbox.

    Fig 14: Illustration For Step

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
46. Clean and fit the dipstick tube.
47. Fit the transmission's breather hose.
48. Fit the shifting cable to the bracket on the transmission. Fit the clamp.
49. Fit the shifting cable to the selector lever in position P.
50. Check and if necessary adjust the position of the selector lever, refer to SELECTOR LEVER CABLE
51. Raise the car. Slacken the bolt securing the front torque arm and center the rubber pad in the arm. Tighten the bolt.

    Tightening torque, torque arm to subframe 90 Nm + 90° (66 lbf ft + 90°) 

    Tightening torque, torque arm to bracket 70 Nm + 90° (52 lbf ft + 90°) 

    Fig 15: Illustration For Step 51

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
52. Lower the car. Plug in the connectors to the transmission.
53. Fit the electrical distribution unit
    Fig 16: Illustration For Step 53-54

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
54. Fit the battery tray, MAXI fuse board, battery and battery cover.
55. Fit the upper engine cover.
56. Fit the front wheels. Tighten to torque. Refer to WHEEL
    IMPORTANT: The wheel must hang freely when the wheel bolts are being tightened.

    Tightening torque 110 Nm (81 lbf ft) 

57. Fill to the correct level with transmission fluid as per Weight, fluid capacity and grade of fluid.
58. If the transmission has been changed and the oil is contaminated FLUSHING EQUIPMENT  must be connected before starting the car. Refer to CLEANING THE COOLING CIRCUIT 
59. Test drive the car with varying engine loads and RPM and read any trouble codes that are generated. Also check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed. Perform ADAPTATION, RESETTING .
60. Set the right time on the clock.