Saab 2000-06

Transaxle Removal & Installation

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  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the transaxle.
  4.  
  5. Remove or disconnect the following:

    Battery
     
    Ground strap from the transaxle housing
     
    Dipstick and sleeve
     
    Vent hose from the transaxle housing
     
    Positive cable routing straps
     
    Transaxle selector lever from housing
     
    Electrical harness on transaxle housing
     
    Oxygen (O 2 S) sensor and securing straps
     

  6.  
  7. Install the engine lifting beam. Insert the lifting bar in the eyelets and connect to the engine holder.
  8.  
  9. Remove or disconnect the following:

    Front wheels
     
    Front exhaust pipes
     
    Front spoilers
     
    Ball joints on both sides
     
    Subframe assembly
     
    Cooler lines from the transaxle
     
    Left and right halfshafts and suspend the shafts with securing straps
     
    Intermediate shaft bearing bracket and pull out the shaft
     
    Actuator cover and release the torque converter's securing point on the actuator
     
    Transaxle mounting bracket
     
    Transaxle mounting bolts that secure the transaxle to the engine
     
    Engine/transaxle surface mounting bolts
     
    2 outer bolts holding the gearbox to the engine mounting surface
     

  10.  
  11. Install the lifting eye to the transaxle and connect the hoist to the transaxle.
  12.  
  13. Remove the last bolt and pull out the transaxle assembly.
  14.  

To install:

  1. Using a hoist lift the transaxle into position.
  2.  
  3. To help with installation use a guide pin to line up the transaxle.
  4.  
  5. When the transaxle is in position, fit the 3 upper bolts into the engine housing.
  6.  
  7. Torque the upper transaxle-to-engine mounting bolts to 55 ft. lbs. (75 Nm). Install the transaxle/engine lifting beam to hold the unit in place.
  8.  
  9. Install or connect the following:

    Transaxle/engine surface mounting bolts and torque the bolts to 55 ft. lbs. (75 Nm)
     
    Transaxle mounting bracket to the transaxle housing and the frame assembly
     
    Torque converter to the actuator with the retaining bolts and torque the bolts to 37 ft. lbs. (55 Nm)
     
    Actuator cover
     
    Intermediate halfshaft with the bracket bearing assembly
     
    Outer halfshafts
     
    Transaxle cooler lines to the transaxle assembly
     
    Sub-frame assembly. Fit the sub-frame bolts and torque the front bolts to 85 ft. lbs. (116 Nm), middle bolts to 141 ft. lbs. (190 Nm), and the rear bolts to 81 ft. lbs. (110 Nm) plus 75° bolt rotation. Torque the ball joints to 55 ft. lbs. (75 Nm).
     
    Front exhaust pipes
     
    Both front wheels
     

  10.  
  11. Fill the transaxle with fluid.

    Selector lever cable and selector lever to the transaxle housing
     
    O 2 S sensor electrical harness
     
    Dipstick and sleeve to the transaxle housing
     
    Positive battery cable
     
    Battery and connect the ground cable
     

  12.  
  13. Test drive the vehicle.
  14.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the transmission fluid.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Front grille
     
    Intake manifold cover
     
    Battery and tray
     
    16 pin and 10 pin wire connectors
     
    Transmission breather hose
     
    Gear selector arm from the transmission
     
    Shifting cable
     
    Cable channel from the engine and gear case, 3.0L engine only
     
    3 upper bolts from the transmission
     
    Dipstick tube
     
    Oxygen (O 2 S) sensor connectors
     
    Rear engine mount nut
     
    3 bolts from the rear engine cushion, loosen only
     

  8.  
  9. Install a lifting beam to the engine and relieve the weight on the engine and transmission.

    Both front wheels
     
    Front exhaust system
     
    Rear engine mount and pad, 2.3L engine only
     
    Steering gear screws
     
    Rear clamps securing the power steering delivery pipe to the subframe
     
    A/C pipes from the subframe holder
     
    Air cleaner casing from the subframe
     
    Engine oil cooler from the charge air cooler, 2.3L engine only
     
    Outer ball joint to steering knuckle bolts
     
    Upper anti-roll bar ball joints
     
    Torque arm from the subframe
     
    Rear support plates
     

  10.  
  11. Position a lifting trolley with a holder under the vehicle. Align the trolley to the subframe.
  12.  
  13. Remove or disconnect the following:
    NOTE
    The crankshaft must be rotated to gain access for all the bolts



    Remaining bolts from the subframe and slightly lower the subframe
     
    Power steering delivery pipe clamps. Lower the lifting trolley and move the subframe aside.
     
    Splash plate, 2.3L engine only
     
    Plug covering the torque converter bolts, 3.0L engine only
     
    Bolts securing the torque converter to the drive plate. Rotate the plate and pulley together.
     

  14.  
  15. Press the torque converter against the transmission to keep the converter in place during transmission removal.

    Torque arm and bracket
     
    Oil cooler inlet and outlet hoses
     
    Left drive shaft and suspend it
     
    Left side engine pad and lower the transmission slightly
     
    Transmission bracket
     
    Transmission from the engine assembly
     
    Transmission from the vehicle
     

  16.  

To install:

  1. Install or connect the following:


  2.  
  3. Rotate the torque converter so that the bolt holes align with the drive plate.
  4.  
  5. Make certain that the 2 guide sleeves are on the engine.
  6.  
  7. Lubricate and install new drive shaft seals.
  8.  
  9. Raise the transmission into position under the vehicle.
  10.  
  11. Install the transmission and torque the bottom bolts between the engine and transmission to 55 ft. lbs. (74 Nm) and the bolts between the transmission and oil pan to 34 ft. lbs. (47 Nm).
  12.  
  13. Remove the lifting beam from the transmission .
  14.  
  15. Install or connect the following:

    Transmission bolts and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Engine pad mount to the transmission and torque the bolts to 62 ft. lbs. (84 Nm)
     
    Bolts securing the engine pad to the body and torque the bolts to 46 ft. lbs. (63 Nm)
     
    Drive shaft and make certain that the circlip snaps into position
     
    Torque converter to drive plate and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Splash plate, 2.3L engine only
     
    Plug covering the torque converter bolts, 3.0L engine only
     
    Cooler hoses and torque the fasteners to 20 ft. lbs. (27 Nm)
     
    Torque arm bracket
     
    Ground cable to the bracket and raise the subframe into position
     
    Power steering delivery pipe clamps
     
    Outer ball joints and A/C pipes
     
    Subframe and rear support plates and torque the subframe bolts to 74 ft. lbs. (100 Nm) plus 45 degrees and the support plate bolts to 44 ft. lbs. (60 Nm)
     
    Outer ball joints to the steering knuckles and torque the bolts to 63 ft. lbs. (85 Nm)
     
    Anti-roll bar link and torque the fastener to 68 ft. lbs. (92 Nm)
     
    Steering gear and torque the bolts to 66 ft. lbs. (90 Nm)
     
    Engine oil cooler and air filter housing, 2.3L engine only
     
    Rear engine cushion
     
    Rear engine mount and torque the bolts to 52 ft. lbs. (70 Nm)
     
    Torque arm to the subframe and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Front exhaust system and torque the bolts to 18 ft. lbs. (24 Nm) on the 2.3L engine. On the 3.0L engine torque the turbo bolts to 18 ft. lbs. (24 Nm) and the exhaust manifold bolts to 30 ft. lbs. (40 Nm).
     
    O 2 S sensor wiring connectors and remove the lifting beam
     

  16.  
  17. Torque the rear engine cushion bolts to 18 ft. lbs. (24 Nm) and the nut to 33 ft. lbs. (45 Nm).

    Engine to transmission and torque the bolts to 52 ft. lbs. (70 Nm)
     
    Cable channel to the transmission, 3.0L engine only
     
    Dipstick tube
     
    Transmission breather hose
     
    Shifter cable to the bracket
     
    Shifter cable to the selector lever. Adjust if necessary.
     
    Torque rod and torque the bolt to 34 ft. lbs. (47 Nm)
     
    Battery tray and battery
     
    Battery cables and cover
     
    Intake manifold cover
     
    Front grille
     
    Front wheels
     

  18.  
  19. Fill the cooling system to the proper level.
  20.  
  21. Fill the transmission to the proper level.
  22.  
  23. Start the vehicle, check for leaks and repair if necessary.
  24.  

 
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