Reconditioning a gearbox, particularly on a Saab 9000, is a complex task that requires mechanical skill, specific tools, and a good understanding of the vehicle’s transmission system. Learn more and access the download manual here……
- Saab 900 vs 9000 vs 9-3 vs 9-5 Acceleration Battle | 0-100 Comparing 7 Saab models by their acceleration from 0 to 100 km/h (0 to 60 mph) 900 (classic) vs 900 (NG) vs 9-3 mk1 vs 9-3 mk2 …
- Saab 9000 Heater Vent Button Hack This simple hack will make those unsightly button posts look good again.
Below is a detailed guide to gearbox reconditioning, including components involved, necessary tools, and step-by-step instructions.
### Components of the Gearbox
1. **Transmission Case**: The outer housing that contains all the internal components.
2. **Gears**: Various gears (input, output, counter) that provide different gear ratios.
3. **Shafts**: Input shaft, output shaft, and countershaft that transmit power through the gearbox.
4. **Synchronizers**: Components that help match the speed of the gears during shifting.
5. **Bearings**: Support the shafts and allow for smooth rotation.
6. **Seals and Gaskets**: Prevent fluid leaks and keep contaminants out of the gearbox.
7. **Shift Forks**: Components that engage the synchronizers and shift gears.
8. **Oil Pump**: Circulates oil to lubricate the internal components.
9. **Transmission Fluid**: Lubricates and cools the gearbox components.
### tools Required
1. **Basic Hand Tools**: Wrenches, sockets, screwdrivers, pliers.
2. **Torque Wrench**: For accurate tightening of bolts.
3. **Pry Bar**: To help separate components.
4. **Gear Puller**: To remove gears from shafts.
5. **Transmission Jack**: To safely support the gearbox during removal and installation.
6. **Clean Workbench**: To organize parts and perform work.
7. **Micrometer/Caliper**: To measure the thickness of gears and bearings.
8. **Parts Cleaner**: For cleaning components.
9. **Sealant**: For reassembling the gearbox.
10. **Service Manual**: To reference specifications and torque settings.
### Step-by-Step Instructions
#### 1. Preparation
– **Safety Measures**: Ensure you wear safety glasses and gloves. Work in a well-ventilated area.
– **Disconnect Battery**: Disconnect the negative terminal from the battery to avoid electrical shorts.
– **Lift the Vehicle**: Use a jack and jack stands to lift the vehicle securely.
#### 2. Remove the Gearbox
– **Drain Transmission Fluid**: Remove the drain plug and let the fluid drain completely.
– **Disconnect Linkages**: Remove any shift linkages connected to the gearbox.
– **Remove Connections**: Disconnect electrical connectors, speed sensors, and any other attachments.
– **Support the Gearbox**: Use a transmission jack to support the gearbox.
– **Unbolt the Gearbox**: Remove the bolts securing the gearbox to the engine and transmission mounts.
– **Carefully Remove the Gearbox**: Gently slide the gearbox away from the engine, ensuring Not to damage any components.
#### 3. Disassemble the Gearbox
– **Clean the Parts**: Before disassembly, clean the exterior of the gearbox to prevent dirt from entering.
– **Remove the Case Bolts**: Unbolt the case, using a torque wrench to carefully open it.
– **Inspect Internal Components**: Once open, inspect gears, bearings, and other components for wear or damage.
– **Remove Gears and Shafts**: Use a gear puller to safely remove gears and shafts from the case.
– **Take Note of Assembly**: Document the positioning of parts or take photos for reference during reassembly.
#### 4. Recondition Components
– **Inspect Gears**: Look for pitting, scoring, or wear on the gear teeth. Replace any that are damaged.
– **Examine Bearings**: Check bearings for smoothness and wear. Replace if they feel rough or are discolored.
– **Replace Seals and Gaskets**: Remove old seals and gaskets. Clean surfaces and install new ones to prevent leaks.
– **Check Synchronizers**: Inspect synchronizers for wear. Replace if they show signs of damage.
– **Clean Components**: Use parts cleaner to thoroughly clean all parts before reassembly.
#### 5. Reassemble the Gearbox
– **Install New Components**: If applicable, install new gears, bearings,
and seals.
– **Lubricate Parts**: Use fresh transmission fluid to lubricate bearings and gears before assembly.
– **Reinstall Gears and Shafts**: Carefully place gears and shafts back into the transmission case.
– **Close the Case**: Align the case halves, then bolt them together following the manufacturer’s torque specifications.
– **Reinstall Shift Forks and Synchronizers**: make sure they are properly aligned and secure.
#### 6. Install the Gearbox
– **Position the Gearbox**: Use the transmission jack to lift the gearbox back into position.
– **Bolt to Engine**: Securely attach the gearbox to the engine using the previously removed bolts.
– **Reconnect Linkages and Connectors**: Reattach shift linkages, electrical connectors, and any other components removed earlier.
– **Refill Transmission Fluid**: Use the appropriate transmission fluid to fill the gearbox.
– **Reconnect Battery**: Reattach the negative terminal of the battery.
#### 7. Testing
– **Lower the Vehicle**: Carefully lower the vehicle off the jack stands.
– **Start the Engine**: Allow the engine to run and check for any unusual noises or leaks.
– **Test Drive**: Take the vehicle for a short test drive to ensure the gearbox operates smoothly and shifts correctly.
### Conclusion
Reconditioning the gearbox on a Saab 9000 is a labor-intensive process that requires careful attention to detail at every step. It’s important to follow the manufacturer’s specifications and guidelines, especially regarding torque settings and fluid types. If you’re Not confident in your mechanical skills, consider seeking the help of a professional mechanic.
Differential fluid, also known as differential oil, is a specialized lubricant designed to ensure the smooth operation of a vehicle’s differential, a critical component of the drivetrain. The differential’s primary function is to allow the wheels to rotate at different speeds, particularly useful when turning corners. This is necessary because the outer wheels travel a longer distance than the inner wheels during a turn.
The differential fluid serves multiple purposes. Firstly, it lubricates the gears and bearings within the differential, minimizing friction and wear, which can lead to premature failure. This lubrication helps maintain optimal operating temperatures, preventing overheating that could damage the differential components. Secondly, differential fluid contains additives that enhance its performance. These additives may include anti-wear agents, detergents, and rust inhibitors, which help protect the metal surfaces within the differential from corrosion and degradation.
Differential fluid can vary by vehicle type and manufacturer, with options including standard gear oil and specialized fluids for limited-slip differentials. Regular maintenance is crucial, as old or contaminated fluid can lead to reduced performance and potential damage. Typically, manufacturers recommend changing differential fluid every 30,000 to 60,000 miles, but this can vary based on driving conditions and vehicle usage. Overall, maintaining proper differential fluid levels and quality is essential for ensuring the longevity and reliability of a vehicle’s drivetrain.