New update kit for manual transmissions

The following is directly from saab cars USA and provided for your information.
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Saab Service and Warranty Reference Library

2002/05/07 RE-ISSUED TO UPDATE GEARBOX FILL INFORMATION
ADDITIONAL INFORMATION UPDATED TO CLARIFY KIT CONTENT AND WARRANTY OPERATION NUMBERS

Date: 03/16/01

To: All Saab Dealers
Saab Service Manager
Saab Parts Manager

From: Rich Miller

Reference: New update kit for manual transmissions

A manual transmission update kit to address various shifting complaints has been developed and added to our parts inventory. See details below. This kit fits the following models:

MY99 - MY01 9-3 up to and including VIN 12029080
MY99 - MY01 9-3 Convertible up to and including VIN 17007508
MY99 - MY01 9-5 up to and including 13025469

If you are rebuilding a transmission before these VINs for any reason, order and install this update kit, Saab P/N 54 40 516.

The first chart shows which parts included in the kit have been improved and, specifically, what the improvements address. The second chart shows a listing of the parts required during an update which are included in the kit. All 9-3 & 9-5 exchange transmissions are updated with the parts included in the kit.

If your customer's complaint is not listed in the first chart, it will likely be necessary to order additional parts to address that complaint since this kit was not developed to address every rebuild situation.

To repair the transmission, follow the instructions as described in WIS. After performing the update, the transmission must be marked with an A as illustrated in the Repair Kit Instruction (included with the kit).
REPAIR KIT P/N 54 40 516 (Please note that all parts in both tables below are included in the Repair Kit)

After gearbox is rebuilt, fill with Saab MTF 0063 Manual Gearbox fluid, p/n 400 132 213.

Complaints	Parts	Part Number
Blocked 2nd gear	Synchromesh hub 1-2	51 64 041
Blocked reverse gear	Reverse Leaf spring Kit	52 57 910
Difficult to engage 3rd-4th gears	Synchromesh rings 3rd-4th Reinforced shift fork 3rd-4th Leaf springs x6	51 60 296 87 49 749 (Kit # 54 40 524) 87 43 791
Difficult to engage 5th gear	Synchromesh sleeve 5th Synchromesh ring 5th Leaf springs x3	52 59 353 51 61 005 (Kit # 54 405 532) 87 43 809
Difficult to disengage 3rd-5th	Selector bearing bracket	54 40 144

Position	Parts	P/N
Gear pos. pin	Plug	43 87 544
Back up light	Gasket	49 40 169
Output shaft	Nut	51 25 323
Reverse assy	O-ring x2	79 67 573
Bearing seat	O-ring	80 47 144
Main case	Sintered compact	87 01 658
Input shaft	Snap ring	87 21 946
Input shaft	Snap ring	87 34 071
Output shaft	Collapsible spacer	87 34 477
Side cover	Gasket	87 34 824
Shift shaft	Sealing	87 41 878
Drive shaft	Sealing x2	87 49 046
Gear case	Flange Sealant	93 21 795
Input shaft	Roller Bearing	52 57 944
Reverse Gear	Reverse support	87 40 672

Thank you for your attention.

Sincerely,
Rich Miller
Manager, Technical Services Quality
Abe Buchbinder
Director, Service & Parts
Saab Cars USA, Inc.

Saab Cars USA, Inc. bulletins are intended for use by professional Saab technicians only, NOT a do-it-yourselfer. They are designed to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Saab trained technicians have the equipment, tools, safety instructions, and know how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle or that your vehicle will have the condition. See your authorized Saab dealer for information on whether your vehicle may benefit from the information. © 2001 Saab Cars USA, Inc.