Manual Transmission Assembly: Adjustment/Replacement: Removal

Open the front hood fully, and support with stay.

Disconnect the ground cable from battery.

Remove the air intake duct and cleaner case. (Saab 9-2X 2.5i Linear)

Remove the air cleaner case stay. (Saab 9-2X 2.5i Linear)

Fig 1: Identifying Air Cleaner Case Stay

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Remove the intercooler. (Saab 9-2X 2.0T Aero)

Disconnect the following connectors:

Neutral position switch connector

Back-up light switch connector

Vehicle speed sensor

Fig 2: Identifying Back-Up Light Switch Connector

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Remove the starter.

Remove the operating cylinder from transmission.

Saab 9-2X 2.5i Linear

Fig 3: Identifying Cylinder Bolts (Saab 9-2X 2.5i Linear)
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Saab 9-2X 2.0T Aero

Fig 4: Identifying Cylinder Bolts (Saab 9-2X 2.0T Aero)
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Remove the pitching stopper.

Fig 5: Identifying Pitching Stopper

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Set the ST.

ST 32005085 ENGINE SUPPORT ASSY

Fig 6: Identifying ST 32005085 Engine Support Assy

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Separate the clutch release fork from release bearing. (Saab 9-2X 2.0T Aero)

Remove the clutch operating cylinder from transmission.

Remove the plug using 10 mm hexagon wrench.

Fig 7: Removing Plug

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Screw the 6 mm dia. bolt into release fork shaft, and then remove it.

Fig 8: Releasing Fork Shaft

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Shaft
Bolt

Raise the release fork and unfasten the release bearing tabs to free release fork.

NOTE: Step (4) is required to prevent interference with engine when removing the engine from transmission.

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

Fig 9: Identifying Right Upper Side Bolts

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

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

Remove the rear exhaust pipe and muffler.

IMPORTANT: When removing the exhaust pipes, be careful each exhaust pipe does not drop out.

Remove the heat shield cover. (If equipped)

Remove the hanger bracket from right side of transmission.

Fig 10: Identifying Hanger Bracket Bolts

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Remove the propeller shaft.

Remove the gear shift rod and stay from transmission.

Disconnect the stay from transmission.

Disconnect the rod from transmission.

Fig 11: Removing Gear Shift Rod

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Stay
Rod

Disconnect the stabilizer link from transverse link.

Remove the bolt securing ball joint of transverse link to housing.

Fig 12: Removing Bolt Securing Ball Joint Of Transverse Link To Housing

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Remove the drive shafts.

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

Fig 13: Identifying Lower Side Bolts

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Place the transmission jack under transmission.

IMPORTANT: Always support the transmission case with a transmission jack.

Fig 14: Placing Transmission Jack Under Transmission

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Remove the transmission rear crossmember from vehicle.

Fig 15: Identifying Transmission Rear Crossmember Bolts

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Remove the transmission.

NOTE:

Move the transmission jack toward rear until main shaft is withdrawn from clutch cover.
Shrink the turnbuckle of ST while lowering the transmission jack to tilt the engine assembly backward.

Separate the transmission assembly and rear cushion rubber.

Remove the clutch release bearing from engine side. (Saab 9-2X 2.0T Aero)