4. Transmission\Automatic Tra...

Bulletins - SI/MI - Cars affected

TECHNICAL SERVICE BULLETIN

Bulletin Nbr: 440-2497
Date:...........Oktober 2004
Market: all
General fault diagnosis for automatic transmission

Cars affected

Saab 9-5 M02-04 with 5-speed automatic transmission

Background

The 5-speed automatic transmission has displayed a number of fault symptoms which are
compiled in the following list of symptoms. The procedure descriptions are included in the
table below.

If the slightest doubt exists over whether the complaint is justified or whether the gearbox is
performing normally, make a comparison with another car of the same type.

Symptom description

Hard, delayed and incorrect shifting, rising engine speed during shifting with various
symptoms.

Procedure

Refer to the list of fault symptoms below and to the table for procedures. There is a checklist
at the end of the document which must be completed and enclosed with replaced gearboxes.

No. Symptom Model year

affected

1 Hard shifting 2-3 during limited acceleration. M02-03

2 Delay and hard shifting P-D and N-D M02-03

3 Delay and hesitation during down shifting 3-2 at 50 - 70 M02-03

km/h

4 Sudden down shifting without reason with cold gearbox and M02-03
at low speed

5 Gear slips in Lock-up mode M02-03

6 Engine speed increases during shifting 2-3 after long periods M02-03
of driving in top gear and then lowering speed to below 20
km/h, accelerating again and shifting up to 3rd gear.

9-5 (9600) 2 2002 1

4. Transmission\Automatic Tra... Bulletins - SI/MI - Cars affected

7 Close shifting at low speed M02-04

8 Hard down shifting when braking to stop M02-03

9 Very hard engagement of positions D and R

10 Noise

11 Diagnostic trouble codes for electrical components

12 Hard down shifting 3-2 M03

13 Oil leakage

Procedure table

The figures refer to the above symptom table.

No. Cause Procedure WIS

1 Incorrect servo a) Check the servo cover, replace

cover for brake B4 if the washer in the cover is
loose.

b) Clear the adaptation values

c) Perform adaptation

d) If possible, compare the

repaired car with a car of the
same type and model.

2 Inertia in valve Replace valve housing with a 9-5 (9600) -

housing valves modified one (part no. 5449780) Transmission -
(SLS, SLT). Automatic Transmission
-
Adjustment/Replacement
- Valve housing

3 Error in TCM Update software in TCM.

software. (Download from IRIS)

4 Problem with speed Replace speed sensor

sensor, normally for
output speed.

9-5 (9600) 2 2002 2

4. Transmission\Automatic Tra... Bulletins - SI/MI - Cars affected

5 A bushing may have a) Check the transmission fluid 9-5 (9600) -

moved and blocked level and quality as well as that Transmission -
the oilways. the oil cooler hoses have Automatic Transmission
unhindered flow. -
Adjustment/Replacement
b) Check if a diagnostic trouble - Complete automatic
code has been detected. Clear transmission or -
the diagnostic trouble code and Automatic Transmission,
test drive the car. fluid level

c) If the diagnostic trouble code

returns, replace the gearbox.

d) If the fault does not reappear,

return the car to the customer.

6 Error in TCM a) Check the transmission fluid 9-5 (9600) -

software. level and quality. Transmission -
Automatic Transmission
b) Update software in TCM. -
(Download from IRIS) M04 has Adjustment/Replacement
modified valve housing and new - Automatic
software. Perform adaptation of Transmission, fluid level
the gearbox.

c) If the problem remains on an

M02-M03 despite the above
procedure, replace the valve
housing, part no. 5449780.
Perform adaptation of the
gearbox.

7 This is a concept None

selection for 5-
speed automatic
transmission.

8 Invalid adaptation. a) Compare the gearbox serial 9-5 (9600) -

number and the software ID Transmission -
number and make sure that they Automatic Transmission
correspond. -
Adjustment/Replacement
b) Clear the adaptation values - Adaptation, resetting
and perform adaptation,
resetting. If the procedures do
not help and the customer
complaints continue, replace the
gearbox.

9 Electrical fault a) Read the value for the 9-5 (9600) -

temperature sensor when the car Transmission -
is cold. Check that the value Automatic Transmission
corresponds with the ambient - Technical data -

9-5 (9600) 2 2002 3

4. Transmission\Automatic Tra... Bulletins - SI/MI - Cars affected

temperature. Transmission fluid

temperature sensor
b) If the value differs too much,
check that the temperature signal
is working. Make sure that the
wiring harnesses and connectors
are working without open circuit

10 Noise a) Determine under which 9-5 (9600) -

conditions the noise occurs (gear Transmission -
position, speed, accelerator pedal Automatic Transmission
position, fluid temperature) -
Adjustment/Replacement
b) Contact the importer /ETAC for - Complete automatic
help. Check whether the noise is transmission
related to engine speed or vehicle
speed by changing gear.

c) Describe the character of the

noise, whining sound, rattling,
clicking etc.

d) Checklist, completed with

gearbox replacement.

11 Diagnostic trouble a) Read out the diagnostic 9-5 (9600) -

codes trouble codes, clear them and Transmission -
test drive the car. Automatic Transmission
- Component location
b) Check the function of the
components identified by the
diagnostic trouble code by
checking whether the diagnostic
trouble code is repeated with a
non-faulty component.

c) Check that the cables and

connectors are working
satisfactorily.

12 Invalid gearbox type a) Check whether the Vehicle

Identification Number and the
gearbox number correspond. (In
certain M03 cars the M04
gearbox has been installed)

b) If the above is in order,

compare the car with another car
of the same type.

13 Oil leakage a) Clean at the leakage and test 9-5 (9600) -

drive the car. Transmission -
Automatic Transmission

9-5 (9600) 2 2002 4

4. Transmission\Automatic Tra... Bulletins - SI/MI - Cars affected

b) If leakage returns, photograph -

the area and mark the area with Adjustment/Replacement
a pen. - Complete automatic
transmission
c) Rectify the leak or replace the
gearbox if necessary. Enclose the
completed checklist and the
photograph when the gearbox is
returned.

Checklist

The list is to be completed and enclosed with the replaced gearbox

Issuer, name and Importer no: Dealer no:

telephone:

Date: Report no:

Car information:

Vehicle Identification Type: Gearbox number:

Number

TCM no: TCM letter code:

Engine type: Mileage:

Customer description of the fault symptom:

Mechanic's report incl. diagnosis:

9-5 (9600) 2 2002 5

4. Transmission\Automatic Tra... Bulletins - SI/MI - Cars affected

Repair attempt:

Conditions when fault Intermittent: ........ Cold gearbox: ........

occurred:

Persistent: ...........
Warm gearbox: .......

When shifting from _______to________

Comments:

Occurs in gear position:

1.......... 2........... 3.......... 4.......... 5.......... Reverse.........

Comments:

Occurs during:

Acceleration: ....... Kick down: ....... Without acceleration: .......

Gentle acceleration: .......

Occurs at engine speed __________ (RPM).

Check performed: gear selector mechanism/adjustment: ........

Mode: Sport: ........ Winter: .........

Normal:.........

Transmission fluid Level checked: ........ Fluid changed: ...........

Other comments:

9-5 (9600) 2 2002 6

4. Transmission\Automatic Tra... Bulletins - SI/MI - Cars affected

Diagnostic trouble codes including symptom supplement before repair and test drive
(e.g. Pxxxx xx):

Diagnostic trouble codes including symptom supplement after repair and test drive (e.g.
Pxxxx xx):

SID display text / warning lamp on in MIU: ...........................

Control module information (read out with diagnostic tool)

Tech2 version:

Software number after SPS programming:

Warranty/Time Information

9-5 (9600) 2 2002 7