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Home >> Saab >> 2004 >> 9-5 Linear, Automatic >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission >> Adjustment/Replacement >> Complete transmission, 4 cyl. diesel >> To remove

To remove

Fig 1: Illustration For Step 1
G03743512Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. Place drapes over the wings and front to keep the paintwork clean and to protect it from damage.
  2. Remove the upper engine cover.
    Fig 2: Illustration For Steps 2-3
    G03743513Courtesy of SAAB-SCANIA OF AMERICA, INC.
  3. Remove the battery cover and the battery.
  4. Remove the MAXI fuse board and remove the battery tray.
    Fig 3: Illustration For Steps 4-5
    G03743514Courtesy of SAAB-SCANIA OF AMERICA, INC.
  5. Undo the main fuse box and move it aside. Use 83 95 212 STRAP  . Undo the cable clip from the main fuse box mounting.
  6. Undo the transmission connector and remove the cable clip.
    Fig 4: Illustration For Steps 6, 7, 8 & 10
    G03743515Courtesy of SAAB-SCANIA OF AMERICA, INC.
  7. Remove the breather hose from the transmission.
  8. Remove the selector lever cable from the selector lever.
  9. Remove the locking clip and carefully bend in the selector cable locking tabs with a suitable screwdriver. Remove the cable from the mounting.
  10. Remove the cable clamp from the starter motor cable.
  11. Remove the vacuum tank together with the mounting bracket.
    Fig 5: Illustration For Step 11
    G03743516Courtesy of SAAB-SCANIA OF AMERICA, INC.
  12. Remove the left-hand heat shield over the exhaust manifold.
    Fig 6: Illustration For Steps 12-14
    G03743517Courtesy of SAAB-SCANIA OF AMERICA, INC.
  13. Remove the three upper bolts from the transmission. For ease of removal use 87 92 723 ACCESS TOOL, BOLTS IN THE AUTOMATIC TRANSMISSION TO ENGINE JOINT  for the rearmost bolt.
  14. Clean around the dipstick tube where it enters the transmission. Remove the dipstick tube and plug the hole.
  15. Remove the nuts from the exhaust pipe.
    Fig 7: Illustration For Steps 15-17
    G03743518Courtesy of SAAB-SCANIA OF AMERICA, INC.
  16. Remove the nut for the rear engine mounting. Use 82 93 102 Extension 500mm, 3/8 square.
  17. Undo the two bolts which hold the rear engine pad. Do not remove the bolts. The third bolt is removed from underneath.
  18. Position 83 94 850 LIFTING BEAM  in place on the engine. Relieve the weight of the engine and transmission.
    Fig 8: Illustration For Step 18
    G03743519Courtesy of SAAB-SCANIA OF AMERICA, INC.
  19. Place a 83 95 212 STRAP  loosely over the radiator crossmember.
  20. Raise the vehicle and remove the front wheels.
  21. Remove the lower engine cover, the spoiler shield and both side covers.
    Fig 9: Illustration For Step 21
    G03743520Courtesy of SAAB-SCANIA OF AMERICA, INC.
  22. Remove the front exhaust system.
    Fig 10: Illustration For Step 22
    G03743521Courtesy of SAAB-SCANIA OF AMERICA, INC.
  23. Remove the rear engine bracket and the engine pad.
    Fig 11: Illustration For Step 23
    G03743522Courtesy of SAAB-SCANIA OF AMERICA, INC.
  24. Remove the two clamps securing the power steering delivery pipe to the subframe.
    Fig 12: Illustration For Step 24
    G03743523Courtesy of SAAB-SCANIA OF AMERICA, INC.
  25. At the same time free the AC pipes from the plastic clips on the subframe.
    Fig 13: Illustration For Step 25
    G03743524Courtesy of SAAB-SCANIA OF AMERICA, INC.
  26. Detach the power steering cooling pipe. Hang up the pipe with a cable tie or something similar.
    Fig 14: Illustration For Steps 26-27
    G03743525Courtesy of SAAB-SCANIA OF AMERICA, INC.
  27. Remove the air cleaner casing from the subframe.
  28. Fit a 83 95 212 STRAP  around the radiator core and the radiator crossmember.
  29. Remove the bolts securing the outer ball joints to the steering swivel member on both sides.
    Fig 15: Illustration For Steps 29-30
    G03743526Courtesy of SAAB-SCANIA OF AMERICA, INC.
  30. Undo the upper anti-roll bar ball joint. Hold with a 17 mm spanner so that the boot does not twist. If the spanner is too wide to fit between the boot and the suspension strut, it must be ground narrower.
  31. Undo the nut on the coolant pipe holder and remove the front bolt on the torque arm.
    Fig 16: Illustration For Step 31
    G03743527Courtesy of SAAB-SCANIA OF AMERICA, INC.
  32. Remove the rear support plates.
    Fig 17: Illustration For Steps 32 & 35
    G03743528Courtesy of SAAB-SCANIA OF AMERICA, INC.
  33. Assemble the holder, use 83 95 170 Adapter, 83 95 196 Holder, front and 83 95 188 BASIC FIXTURE  . Put the assembled tool on a 83 95 311 LIFTING TROLLEY  .
  34. Place the lifting trolley with lifting table and holder under the subframe. Lift up the lifting table, be careful to position it correctly. Push aside the battery cooling pipe sufficiently to avoid the trolley guide pin.
  35. Remove the last 4 bolts securing the subframe. Lower the subframe slightly and detach the steering gear.
  36. Detach the suspension arms from the steering swivel member, lower the subframe and remove the lifting trolley.
  37. Remove the starter motor heat shield.
    Fig 18: Illustration For Step 37
    G03743529Courtesy of SAAB-SCANIA OF AMERICA, INC.
  38. Detach the starter motor electrical connections and remove the starter motor.
    Fig 19: Illustration For Step 38
    G03743530Courtesy of SAAB-SCANIA OF AMERICA, INC.
  39. Undo the 3 bolts securing the torque converter to the drive plate. Rotate the engine in the normal rotational direction using the drive belt pulley.
    Fig 20: Illustration For Step 39
    G03743531Courtesy of SAAB-SCANIA OF AMERICA, INC.
  40. Remove the remaining bolts holding the transmission except for one which must remain to hold the transmission in place. Remove the rubber plug and press the torque converter towards the transmission and fit 87 92 574 HOLDER  to keep the torque converter in place while the transmission is removed. The torque converter may need to be rotated slightly in order to fit the holder.
    Fig 21: Illustration For Steps 40, 41, 42, 44 & 45
    G03743532Courtesy of SAAB-SCANIA OF AMERICA, INC.
  41. Disconnect the ground leads.
  42. Remove the torque arm together with the bracket.
  43. Drain the transmission fluid, fit the drain plug with a new sealing washer.

    Tightening torque 40 Nm (30 lbf ft) 

  44. Disconnect the oil cooler inlet and outlet hoses. Plug the inlet and outlet passages on the transmission and also plug the hoses. Use plug no. (10) 91 32 929 and seal no. (10) 91 32 937.
  45. Detach the left-hand drive shaft with 87 92 616 REMOVAL TOOL, DRIVE SHAFTS  . Detach the ABS cable and the brake hose from the holder.
  46. Suspend the shaft by means of a 83 95 212 STRAP  .
  47. Lower the vehicle and remove the left-hand engine pad.
    Fig 22: Illustration For Step 47
    G03743533Courtesy of SAAB-SCANIA OF AMERICA, INC.
  48. Lower the unit about 70 mm measured at the transmission mounting bracket. Remove the mounting bracket from the transmission.
    Fig 23: Illustration For Step 48
    G03743534Courtesy of SAAB-SCANIA OF AMERICA, INC.
  49. Raise the vehicle, fit 87 92 608 HOLDER FOR PILLAR JACK  on a pillar jack. Adjust and secure the holder to the transmission as shown in the illustration. Use a bolt that is approx. 20 mm longer than that removed and a nut and bolt for the rear lifting eye.
    Fig 24: Identifying Pillar Jack
    G03743535Courtesy of SAAB-SCANIA OF AMERICA, INC.
  50. Remove the remaining bolts securing the transmission to the engine.
  51. Pull out and lower the transmission casing.
    IMPORTANT: The pillar-type jack may tip over. Exercise care.
  52. Lift down the gearbox from the pillar jack using an engine hoist and 87 92 442 LIFTING CABLE  while removing the lifting tool from the transmission.
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