The autos are junk - Borg Warner three-speeds that are commonly swapped out for manuals. Bad mileage, slow, heavy, high-revving on the highway, ick.
The swap is pretty straightforward; there is a PDF with good instructions at Saabnet; however, you may have to hunt around the site a bit - usability isn't the greatest. You MUST install the oil pick-up from the manual transmission, which is a different length than the auto's. Unless the motor's been out recently, it's probably not a bad idea to do the front seal (firewall side) as well as oil pump seal. Alternator bushings (NO polyurethane, just rubber) are easy to do at this time, as is the steering rack if the '91's happens to have 'morning sickness.' Water pump is easy then, and, especially, the exhaust manifold gasket, too. (Hand-snug the bolts with a short wrench, don't use the torque spec, as aftermarket studs can snap.) Note: ASSuming your FiL's 900 isn't a Turbo: you'll want to get a 7-piece Turbo clutch kit for a pre-90 900 Turbo, NOT for a '91 Turbo. Saab changed to a different clutch for Turbos in '90 and the later pressure plate will NOT fit the '88 flywheel that you already have on hand.
(The earlier Turbo clutch parts are cheaper, btw, and there is no advantage to using the later Turbo clutch - Saab only did it to save money: the 900 and 9000 clutches were the same that year.) When you do the swap, it's a good idea to fit a new rear main seal ( front of the engine behind flywheel). Make your own seal driver with a piece of plastic plumbing from Home Depot (bring the seal with you to find the right size) Search 'homemade seal driver' or 'homemade rear seal tool' on Saabnet. I have found a 5-gallon bucket handle to work best for the 'clutch tool' you'll need to remove the clutch.
I don't know if you can use the existing console between the seats. If not, then note that the console between the seats in the '88 is different than the '91 - Saab was by then fitting 9000 seats, which are wider so the console was narrowed. That said, if your FiL's '88 has passive seatbelts then the seats will fit in the '91 (along with the '88 console), as they have the same bolt pattern. You might run into issues with the plumbing to the turbo. The hard water line to the turbo is different between manuals and autos. Unfortunately, the hard water line does not have a part number stamped on it and I'd be stunned if the lines are still available so you may need to make a trip to a junkyard.
Www.eEuroparts.com is the cheapest place for Saab parts. C900 transmissions will last longer if you change their oil annually. Redline MTL or MTF (can't recall the acronym) works well unless you're in a really hot climate or drive really hard, in which case it's a bit thin. Feel free to email me with any questions. While I haven't done the swap, for better or worse, I've had my hands in a good number of c900s (did a clutch two weeks ago) and currently own two c900s and ran one in the Alcan 5000 in Feb.
So after having done done light mods to my car, I just love it! I'm addicted and can't get enough torque But since my car is automatic, it's limited as far as how much I can do to it. As of right now my tires brake loose in 1st and 2nd gear. I'm afraid transmission will not last much longer. So I've decided to start looking around for a donor car with a manual. At first I've considered selling mine and buying another 9-5 but manual, however I've put too much money in this car, and I know that almost everything is up-to-date so I don't want to give up on it.
From some reading that I've been doing I found not many people have done this, so just wondering if anyone on here has and if you guys have tips/suggestions? The donor car will be a 1999 Saab 9-5 Linear and my car is a 2003 Saab 9-5 Aero. The transmissions should be interchangeable, right?
The in the is slow, inefficient and often unreliable. Converting to a manual transmission transforms an automatic car into the efficient performance machine the 900 was meant to be.
The conversion can be completed by the Do-It-Yourself mechanic with intermediate mechanical skills. All that is required are tools, time and this website as your guide.
These instructions apply to all 1979-1993 900 models including the '94 convertible. A printer-friendly version is available in Adobe PDF format.
SAAB 900 Automatic to Manual Conversion This Document serves both as a record of a project on a 1984 Saab 900, and as a reference for do-it-yourselfers who wish to convert from automatic to manual shift. These notes apply only to the 1979-1993 Saab 900 including the 1994 convertible. Saab 95 Neutral Position Switch (NPS or NSS) ReplacementIntermittent car won’t start typically after short trip (10 minutes or so) Rowing gear selector back and forth sometimes is a short term fix.I was unable to find a 95 DIY instruction so I made this one. However, there is a well documented replacement procedure on the NG900 and OG93 BB (search Neutral Safety Switch).
Saab 9000 Auto To Manual Conversion Guide
After reading that one I believe it is easier to do on the 95 – procedure follows. Here is the owners manual for the Saab 900s SE, I apologize if this is not the actual Chilton manual if you find it forward it to me so I can have it published here.Thanks Manual for Saab 900. Year make 1996. Instrukcja do Saab 900 rocznik 1996.
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The in the is slow, inefficient and often unreliable. Converting to a manual transmission transforms an automatic car into the efficient performance machine the 900 was meant to be. The conversion can be completed by the Do-It-Yourself mechanic with intermediate mechanical skills. All that is required are tools, time and this website as your guide. These instructions apply to all 1979-1993 900 models including the '94 convertible.
A printer-friendly version is available in Adobe PDF format.