Gearbox Side Cover - Identification
89saab07FILE IN VOL.
S.I. Man. I
SEC. PG.
B-4 24
Issue: 10/89-1182
Subject: Gearbox Side Covers
Application: 9000 Models with Manual Transmission
During the course of production, several styles of side covers have been used on the 9000 5-speed manual gearbox. Failure to use the proper side cover with respect to the gearbox type may result in complaints of reverse engagement difficulties, popping out of reverse gear, improper operation of the back-up lights, damage to the back-up light switch, or improper operation of the upshift light.
The side covers can be identified by the number of threaded holes used for fitting the back-up light and upshift light switches. Measurements can also be taken to further distinguish one cover from another.
For a short period of time, newly built gearboxes for 1986 model 9000's were produced using a modified side cover which requires that a steel washer 2.0 mm thick be installed under the back-up light switch. The washer is supplied with the gearbox and is located under the plastic transportation plug fitted into the threaded hole for the back-up light switch. The gearboxes that are affected by this modification have a variant designation of GMT 5301, supplied under exchange P/N 88 23 692, with serial numbers C01800-C01875. The modification to the side cover is described in 9000 Service Manual 4:1, page 471-41, step 36.
Figure 1 - Side Cover Measurements.:
Measurement of Side Covers
Two dimensions of the side cover can be measured which help identify them as shown in Figure 1.
O = Back-up switch guard length (measured from end of guards to switch sealing surface).
I = Back-up switch depth (measured from gasket surface to switch boss).
The chart below lists each side cover that has been used during the production of the 9000 manual transmission. If you suspect that a complaint is related to the side cover, compare the cover in question with this information and take the necessary corrective action.