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Old 02-25-2019, 05:47 AM   #1
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9-5 auto to manual - revisited

For real looking to swap my '08 auto to a manual. I know it can be done and I'm willing to pay to have it done. The auto in the car now is junk and needs replacement anyway. The days of simply being able to "go find a stick" are long gone. The car is solid and I just updated the entire suspension with all new parts. Engine runs well, body is pretty good and I consider the car to be worth putting some more $ into.

So seriously... what all is involved and who wants to help me/make some money off me to do this swap?

I know there is some electrical wizardry involved, but other than the obvious mechanical stuff and welding in a bracket for the clutch pedal, what all is there really to it?
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Old 02-25-2019, 06:21 AM   #2
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Buy a stick parts car, preferably 06+. I think the pedal pack is going to be the major pain in the nuts in this swap. Tearing down 2 and reassembling 1 is going to be a HUGE amount of labor. Even I would have to quote you thousands

I can swing you a good deal replacing the auto

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Old 02-25-2019, 06:27 AM   #3
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$2-3K is honestly kind of what I was budgeting...
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Old 02-25-2019, 06:29 AM   #4
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Realistic budget. I think you'll hit the high end easily
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Old 02-25-2019, 06:34 AM   #5
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I'm probably insane...
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Old 02-25-2019, 07:38 AM   #6
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I asked my Saab tech uncle about it once and he laughed at me and said expect 40 hours labor plus a parts car and whatever parts you'd want to buy new, like clutch disc etc.
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Old 02-25-2019, 08:46 AM   #7
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it does sound pretty absurd.

Scott... how much to swap a good used auto in?
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Old 02-25-2019, 10:48 AM   #8
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I'm really just going car crazy. Hate to get out of a 9-5, but missing the stick big time and hard to justify buying a nice one (and most likely having to ship it). I'd rather put that kind of money towards a newer, possibly even nicer car.

Been shopping around for Fiesta ST's, Focus ST, and even Merc 350 wagons (the 2011's have finally come WAY down in price).
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Old 02-25-2019, 02:37 PM   #9
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Call up Harvey's Autohauss. I bet he'd be willing to tackle it for a reasonable rate. Though it's a bit of a drive from you... Maybe Mike D?
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Old 02-25-2019, 02:48 PM   #10
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Harvey had crossed my mind, and I talked to MikeD about it briefly.
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Old 02-25-2019, 02:58 PM   #11
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I should mention... I have a shop with a lift, and am not afraid to get dirty on this one. Just looking for advice and someone more proficient than I am in drivetrain type stuffs to lend me a hand (for a fee of course).
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Old 02-26-2019, 06:23 AM   #12
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Frank Bialy just did this on his Aero wagon a couple of months ago. I don't know if he is on Saablink, but you can find him on facebook. Beautiful car.
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Old 02-26-2019, 06:36 AM   #13
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Here is a picture that Frank sent me when I asked him about it a couple of months ago. I was going to manual swap my 9-5 sedan with weird TCM issues before I sold it.

I am always disappointed by people shooting these projects down. Yes, it will be alot of work. But the gains are worth it for the right car. I say go for it. You also don't NEED a parts car. I pulled most everything I needed from a junkyard.

I'll start a list:

- Transmission
- Transmission mounts
- Flywheel
- Clutch
- Master cylinder
- Slave
- Clutch line
- Shifter
- Shifter Linkage
- Pedals
- Brake fluid reservoir
- MIU (Instrument cluster)
- Rear motor mount (from memory)
- I'm pretty sure you'll need both axles
- The PVC plumbing is different as I'm pretty sure the manual setup doesn't use a vacuum pump (I'd buy
all that junk new if possible)

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-1992 9000 T5
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-2004 9-5 Aero Wagon - Glacier Blue

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Old 02-26-2019, 06:43 AM   #14
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Not even sure if the 06+ requires a different MIU as the gear indicator is part of the LCD.

Edit: Confirmed, no difference in clusters for AT vs MT in 06+

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Old 02-26-2019, 07:17 AM   #15
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PCV looks the same. However, the vacuum line from the brake booster to the SAI pump is different.

Call out 26 for MT vs 36 for AT
https://www.esaabparts.com/viewparts...tion=352935051

When you remove the SAI pump, you'll need a camshaft seal:
https://www.esaabparts.com/saab/parts/9135211
or some bling:
https://genuinesaab.com/catalog/prod...id8rl3hul10s70
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Old 02-26-2019, 07:36 AM   #16
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Quote:
Originally Posted by srp View Post
PCV looks the same. However, the vacuum line from the brake booster to the SAI pump is different.

Ah, yeah...that. I knew something was different there.
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Old 02-26-2019, 07:49 AM   #17
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Some good info here: https://www.saabcentral.com/forums/s...d.php?t=529290
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Old 02-26-2019, 02:14 PM   #18
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I remember reading through that thread on SC, definitely some good stuff in there.
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Old 07-23-2019, 01:35 PM   #19
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Swaping automatic tranny for another one is doable.

My previous high was changing brakepads and stuff.

Bought dinor with blown engine for 500e, swapped the tranny out in 7 days of on off work without a lift, just 2 crocodile jacks ( one is low cost and this made me drop a car from it) borrowed one from local tyre shop, without it it would really dangerous and hard


For any question I will try to assist from memory

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