PRE-RELEASE
Bush and gear linkage breakage
| SERVICE INFORMATION | |
| Bulletin Nbr: | 432-2024 |
| Date: ........... | October 1998 |
| Market: | all |
| Bush and gear linkage breakage |
| Cars affected |
Saab 900 M94-96 with manual, alternatively Sensonic gearbox
| Background |
A problem has arisen with the gear shifting on certain cars that makes it difficult to change gear. This is caused by a bush connecting the front gear rod with the gear linkage breaking under stress. The problem has been especially evident on cars that have been driven hard and aggressively in warm climates.
The solution is to install an improved linkage assembly.
| Parts required |
46 26 321 Linkage (CA: 30579660)
46 26 677 Ball stud (CA: 30564619)
46 26 537 Seal (CA: 30564607)
| Procedure |
| 1. |
Place the car on a lift.
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| 2. |
Engage 4th gear.
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| 3. |
Remove the plastic plug on the gearbox and insert lock pin 87 92 335 (with the ring up) to lock the gearbox in 4th gear.
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| 4. |
Undo the nut securing the gear rod to the linkage in the gearbox. Use a 13 mm spanner.
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| 5. |
Move the gear lever to 3rd gear position so that the gear rod slides out of the linkage. Remove the screw securing the linkage to the gearbox.
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| 6. |
Raise the car.
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| 7. |
Remove the gear linkage.
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| 8. |
Remove the rubber boot above the “lug”.
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| 9. |
Saw off the “lug” containing the plastic bush in the rear engine mounting.
File off any burrs. |
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| 10. |
Remove the top rear screw on the seal retainer with Torx key 40.
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| 11. |
Fit the ball stud into the screw hole.
Tightening torque: 22 Nm (16 lbf ft) |
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| 12. |
Fit the seal.
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| 13. |
Position the new gear linkage on the gear rod in the gearbox.
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| 14. |
Position the ball stud and apply the lock mechanism.
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| 15. |
Lower the car
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| 16. |
Screw together the gear linkage with the gear rod in the gearbox.
Tightening torque: 22 Nm (16 lbf ft) |
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| 17. |
Lift up the gear lever boot with surround.
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| 18. |
Engage 4th gear and insert lock pin 87 92 335 into the gear shift housing with the ring up.
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| 19. |
Tighten the nut on the clamp by the gear rod. Use a 13 mm spanner.
Tightening torque: 22 Nm (16 lbf ft) |
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| 20. |
Remove the lock pin in the gearbox and press the plastic plug into the hole.
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| 21. |
Remove the lock pin in the gear shift housing.
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| 22. |
Fit the gear lever boot.
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| 23. |
Try changing gear and see if the gear lock works.
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| Warranty/Time Information |
Failed Object: 43245
Fault/Reason code: 71
Location code: 09
Warranty type (US): 01
Repair/Action code: 05
Labor Operation (US): 43245 0.4, straight time 0.1
(CA: K1270, 0.5 hr)
Time: 0.5 h
