Manual Transmission Assembly: Adjustment/Replacement: Installation

Install the rear cushion rubber to transmission assembly.

Tightening torque: 

35 Nm (3.57 kgf-m, 25.8 ft-lb) 

Install the clutch release lever and bearing onto transmission. (Saab 9-2X 2.0T Aero)

Install the transmission onto engine.

Gradually raise the transmission with transmission jack.

Loosen the turnbuckle of ST to return the engine assembly to its original position.

Engage them at splines.

Install the transmission rear crossmember.

Tightening torque: 

T1: 70 Nm (7.1 kgf-m, 51 ft-lb) 

T2: 140 Nm (14.3 kgf-m, 103 ft-lb) 

Take off the transmission jack.

Tighten the nuts which hold the lower side of transmission to engine.

Tightening torque: 

50 Nm (5.1 kgf-m, 36.9 ft-lb) 

Connect the engine and transmission.

Install the starter.

Tighten the bolt which holds right upper side of transmission to engine.

Tightening torque: 

50 Nm (5.1 kgf-m, 36.9 ft-lb) 

Remove the ST.

Install the pitching stopper.

Tightening torque: 

T1: 50 Nm (5.1 kgf-m, 37 ft-lb) 

T2: 58 Nm (5.9 kgf-m, 43 ft-lb) 

Lift-up the vehicle.

Replace the differential side retainer oil seal.

Install the front drive shaft into transmission.

ST 32005040 FRONT DRIVE SHAFT OIL SEAL PROTECTOR 

Install the ball joints of lower arm into knuckle arm of housing, and tighten the installing bolts.

Tightening torque: 

49 Nm (5.0 kgf-m, 36 ft-lb) 

1. Transverse link
2. Ball joint

Install the stabilizer link from transverse link.

Tightening torque: 

30 Nm (3.1 kgf-m, 22.1 ft-lb) 

Install the gear shift rod and stay.

Install the gear shift rod onto transmission.

1. Stay
2. Rod

Install the stay onto transmission.

Install the propeller shaft.

Install the heat shield cover. (If equipped)

Install the hanger bracket on right side of transmission.

Install the rear exhaust pipe and muffler.

Install the front exhaust pipe and center exhaust pipe. (Saab 9-2X 2.5i Linear)

Install the center exhaust pipe. (Saab 9-2X 2.0T Aero)

Install the under cover.

Push the clutch release lever to fit the bearing into clutch cover. (Saab 9-2X 2.0T Aero)

Install the operating cylinder.

Tightening torque: 

37 Nm (3.8 kgf-m, 27.5 ft-lb) 

• Saab 9-2X 2.5i Linear
  Fig 13: Installing Operating Cylinder (Saab 9-2X 2.5I Linear)

  Courtesy of SAAB-SCANIA OF AMERICA, INC.
• Saab 9-2X 2.0T Aero
  Fig 14: Installing Operating Cylinder (Saab 9-2X 2.0T Aero)

  Courtesy of SAAB-SCANIA OF AMERICA, INC.

Connect the following connectors:

Transmission ground cable

Tightening torque: 

13 Nm (1.3 kgf-m, 9.4 ft-lb) 

Vehicle speed sensor connector

Neutral position switch connector

Back-up light switch connector

Install the air cleaner case stay.

Tightening torque: 

16 Nm (1.6 kgf-m, 11.6 ft-lb) 

Install the air cleaner case and duct.

Connect the battery ground cable to battery.

Take off the vehicle from lift arms.