SAAB WIS ONLINE

SPECIFICATION

SPECIFICATION

MANUAL TRANSMISSION AND DIFFERENTIAL

Model

Saab 9-2X 2.5i Linear

Saab 9-2X 2.0T Aero

Type

5-forward speeds with synchromesh and 1-reverse

Transmission gear ratio

1st

3.454

3.454

2nd

2.062

1.947

3rd

1.448

1.366

4th

1.088

0.972

5th

0.780

0.738

Reverse

3.333

Front reduction gear

Final

Type of gear

Hypoid

Gear ratio

3.900

Rear reduction gear

Transfer

Type of gear

Helical

Gear ratio

1.000

1.100

Final

Type of gear

Hypoid

Gear ratio

3.900

3.545

Front differential

Type and number of gear

Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)

Center differential

Type and number of gear

Straight bevel gear (Bevel pinion: 2, Bevel gear: 2 and viscous coupling)

Transmission gear oil

GL-5

Transmission oil capacity

3.5 litres (3.7 US qt, 3.1 lmp qt)



TRANSMISSION GEAR OIL

Recommended oil:


(1)

Item

(2)

Transmission gear oil

(3)

API classification

(4)

SAE viscosity No. and applicable temperature



TRANSMISSION CASE ASSEMBLY

Drive pinion shim adjustment

Hypoid gear backlash:

0.13 — 0.18 mm (0.0051 — 0.0071 in)

Drive pinion shim
Part No. Thickness mm (in) Part No. Thickness mm (in)
32006727

0.150 (0.0059)

32006731

0.250 (0.0098)

32006728

0.175 (0.0069)

32006732

0.275 (0.0108)

32006729

0.200 (0.0079)

32006733

0.300 (0.0118)

32006730

0.225 (0.0089)

32006734

0.500 (0.0197)



Selection of main shaft rear plate

Main shaft rear plate
Dimension “A” mm (in) Part No. Mark
4.00 — 4.13

(0.1575 — 0.1626)

32006725

1

3.87 — 3.99

(0.1524 — 0.1571)

32006726

2



DRIVE PINION ASSEMBLY

Preload adjustment of thrust bearing

Starting torque:

0.3 — 0.8 Nm (0.03 — 0.08 kgf-m, 0.2 — 0.6 ft-lb)

Adjusting washer No. 1
Part No. Thickness mm (in)
32008260

3.925 (0.1545)

32008261

3.950 (0.1555)

32008262

3.975 (0.1565)

32008263

4.000 (0.1575)

32008264

4.025 (0.1585)

32008265

4.050 (0.1594)

32008266

4.075 (0.1604)



Adjusting washer No. 2
Part No. Thickness mm (in)
32008268

3.850 (0.1516)

32008263

4.000 (0.1575)

32008267

4.150 (0.1634)



REVERSE IDLER GEAR

Adjustment of reverse idler gear position

Reverse idler gear to transmission case (LH) wall clearance:

6.0 — 7.5 mm (0.236 — 0.295 in)

Reverse shifter lever
Part No. Mark Remarks
32006772

7

Further from case wall

32006773

8

Standard

32006774

9

Closer to the case wall



After installing a suitable reverse shifter lever, adjust the clearance using washers.

Reverse idler gear to transmission case wall clearance:

0 — 0.5 mm (0 — 0.020 in)

Washer (20.5 × 26 × t)
Part No. Thickness mm (in) Part No. Thickness mm (in)
32008255

0.4 (0.016)

32008258

1.9 (0.075)

32008256

1.1 (0.043)

32008259

2.3 (0.091)

32008257

1.5 (0.059)

—

—



SHIFTER FORK AND ROD

Select the suitable shifter forks so that both coupling sleeve and reverse driven gear are positioned in the center of their synchromesh mechanisms.

Rod end clearance:

A: 1st-2nd — 3rd-4th

0.4 — 1.4 mm (0.016 — 0.055 in)

B: 3rd-4th — 5th

0.5 — 1.3 mm (0.020 — 0.051 in)

1st-2nd shifter fork
Part No. Mark Remarks
32006758

1

Approach to 1st gear by 0.2 mm (0.008 in)

32006759

No mark

Standard

32006760

3

Approach to 2nd gear by 0.2 mm (0.008 in)



3rd-4th shifter fork
Part No. Mark Remarks
32006762

1

Approach to 4th gear by 0.2 mm (0.008 in)

32006763

No mark

Standard

32006764

3

Approach to 3rd gear by 0.2 mm (0.008 in)



5th shifter fork (Saab 9-2X 2.5i Linear)
Part No. Mark Remarks
32006765

7

Approach to 5th gear by 0.2 mm (0.008 in)

32006766

No mark

Standard

32006767

9

Become distant from 5th gear by 0.2 mm (0.008 in)



5th shifter fork (Saab 9-2X 2.0T Aero)
Part No. Mark Remarks
32006768

7

Approach to 5th gear by 0.2 mm (0.008 in)

32006769

No mark

Standard

32006770

9

Become distant from 5th gear by 0.2 mm (0.008 in)



TRANSFER CASE OR REAR CASE

Neutral position adjustment

Adjusting shim
Part No. Thickness mm (in)
32006705

0.15 (0.0059)

32006706

0.30 (0.0118)



Reverse accent shaft
Part No. Mark Remarks
32006697

S

Neutral position is closer to 1st.

32006698

T

Standard

32006699

U

Neutral position is closer to reverse gear.



Reverse check plate adjustment

Reverse check plate
Part No. Mark Angle &thetas; Remarks
32006700

0

28°

Arm stops closer to 5th gear.

32006701

1

31°

Arm stops closer to 5th gear.

32006702

2

34°

Arm stops in the center.

32006703

3

37°

Arm stops closer to reverse gear.

32006704

4

40°

Arm stops closer to reverse gear.



EXTENSION ASSEMBLY

Thrust washer (50 × 61 × t) to taper roller bearing table outer race side clearance:

0.2 — 0.3 mm (0.0008 — 0.012 in)

Note

Be sure to keep the clearance within specifications.


Thrust washer (50 × 61 × t)
Part No. Thickness mm (in)
32008283

0.50 (0.0197)

32008284

0.55 (0.0217)

32008285

0.60 (0.0236)

32008286

0.65 (0.0256)

32008287

0.70 (0.0276)

32008288

0.75 (0.0295)

32008289

0.80 (0.0315)

32008290

0.85 (0.0335)

32008291

0.90 (0.0354)

32008292

0.95 (0.0374)

32008293

1.00 (0.0394)

32008294

1.05 (0.0413)

32008295

1.10 (0.0433)

32008296

1.15 (0.0453)

32008297

1.20 (0.0472)

32008298

1.25 (0.0492)

32008299

1.30 (0.0512)

32008300

1.35 (0.0531)

32008301

1.40 (0.0551)

32008302

1.45 (0.0571)



Thrust washer to center differential side clearance:

0.15 — 0.35 mm (0.0059 — 0.0138 in)

Thrust washer
Part No. Thickness mm (in)
32008270

0.9 (0.035)

32008274

1.0 (0.039)

32008271

1.1 (0.043)

32008275

1.2 (0.047)

32008272

1.3 (0.051)

32008276

1.4 (0.055)

32008273

1.5 (0.059)

32008277

1.6 (0.063)

32008278

1.7 (0.067)



FRONT DIFFERENTIAL

Bevel gear to pinion backlash:

0.13 — 0.18 mm (0.0051 — 0.0071 in)

Washer (38.1 × 50 × t)

Part No.

Thickness

mm (in)

Part No.

Thickness

mm (in)

32008279

0.925 — 0.950 (0.0364 — 0.0374)

32008281

1.025 — 1.050 (0.0404 — 0.0413)

32008280

0.975 — 1.000 (0.0384 — 0.0394)

—

—



TRANSFER DRIVE GEAR

Snap ring (Outer-30) to ball bearing clearance:

0.01 — 0.15 mm (0.0004 — 0.0059 in)

Snap ring (Outer-30)
Part No. Thickness mm (in)
32008338

1.53 (0.0602)

32008339

1.65 (0.0650)

32008340

1.77 (0.0697)