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2nd gear is AWoL

6.5K views 31 replies 8 participants last post by  zingZACH  
#1 · (Edited)
Second gear on my manual C900SE is toast it seems. It goes from 1st to 4th unless I put it into 3rd from 1st. Also noticed that 1st gear feels a bit forced when I engage it.


***Resolved however reading this may help people that have similar problems***
 
#2 ·
Try rev matching to see if it will go in without grinding. If not, your synchro may be bad. On my car I run it up to about 3K in first, depress the clutch and watch for the needle to drop to 2k and it will slip right in just as the needle passes. Downshifting is a little more involved depending on mph and revs.

Did this come on on its own, or have you recently done work on the car? It could be something as simple as an alignment issue.
 
#5 ·
Our c900 kinda does the same thing. I found I could get it in 2nd by slamming it over to the 5th/R gate and then all the way back into 2nd. The coupler seems to be intact, we figured it just needed the shifter aligned, but since we don't drive it that much, havent gotten around to it.

It does however go from 1st to 2nd just fine, it just does it when downshifting
 
#10 ·
Check that the shifter mount is secure. Three bolts hold the ring at the pivot point of the shifter. Often one works its way out and has the result you're experiencing.
 
#12 ·
Peal the shift boot up off the console, you'll see right through the square hole how it mounts. Bolts are actually a 3-lobe odd looking thing. Easily replacable with standard 6-sided bolts.
 
#15 ·
If you're just missing the gate, that def sounds like a shifter alignment issue. Now that you know how to access the shifter retainer, the next thing I would do is take the shifter out and inspect it for breakage or excessive wear. Take the three small torx screws out that hold the shifter into the shifter housing and pull the whole shifter out.

If I recall, the '91 has the "plastic-ball" shifter. The upper pivot ball is actually a two piece ball with a large spring inside. The lower half of the upper ball extends down to the lower ball and is held to the shifter shaft with a retaining pin. check to see that nothing has broken. Sometimes the plastic piece breaks near the retaining pin.

If that checks out OK, then the other suspects are that the shifter housing (connected to the car floor) has come loose and is moving. In order to access the "special nuts" that hold it to the car you'd need to remove the center floor console. Those nuts would have to be tightened with a special wrench. You can make one by grinding down a 10mm socket (check the "SAAB tools" thread).

A couple other possibilities would be the shaft bushing at the front of the shifter housing is bad. I've seen them get destroyed by weld splatter on the shifter/transmission connecting shaft. To replace that bushing, you'd have to remove the whole shifter housing--big project if you're not handy. It could also be the bushing at the shift linkage where the shaft from the cabin meets the shaft on the transmission. That linkage is underhood near the firewall above the steering rack. I can't recall if the '91 has the newer "dogbone" style or the older cylindrical one.
 
#16 ·
If you're just missing the gate, that def sounds like a shifter alignment issue. Now that you know how to access the shifter retainer, the next thing I would do is take the shifter out and inspect it for breakage or excessive wear. Take the three small torx screws out that hold the shifter into the shifter housing and pull the whole shifter out.

If I recall, the '91 has the "plastic-ball" shifter. The upper pivot ball is actually a two piece ball with a large spring inside. The lower half of the upper ball extends down to the lower ball and is held to the shifter shaft with a retaining pin. check to see that nothing has broken. Sometimes the plastic piece breaks near the retaining pin.

If that checks out OK, then the other suspects are that the shifter housing (connected to the car floor) has come loose and is moving. In order to access the "special nuts" that hold it to the car you'd need to remove the center floor console. Those nuts would have to be tightened with a special wrench. You can make one by grinding down a 10mm socket (check the "SAAB tools" thread).

A couple other possibilities would be the shaft bushing at the front of the shifter housing is bad. I've seen them get destroyed by weld splatter on the shifter/transmission connecting shaft. To replace that bushing, you'd have to remove the whole shifter housing--big project if you're not handy. It could also be the bushing at the shift linkage where the shaft from the cabin meets the shaft on the transmission. That linkage is underhood near the firewall above the steering rack. I can't recall if the '91 has the newer "dogbone" style or the older cylindrical one.
My fear is that I may damage it more but I will take the housing off to inspect it. I really want that short shift kit you spoke about once on here.
 
#20 ·
That's fine, as long as the rest of the parts aren't spinning on the shaft. That part is held on to the other parts with a bushing. If it's spinning REALLY freely and has a little wobble to it, the internal bushing could be worn. It can turn, but it should have a little resistance to it and definitely shouldn't wobble.