Saab '03-'04 6 speed ratios & RPO

Real tech discussion on design, fabrication, testing, development of custom or adapted parts for Pontiac Fieros. Not questions about the power a CAI will give.

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The Dark Side of Will
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Re: Saab '03-'04 6 speed ratios & RPO

Post by The Dark Side of Will »

Shaun41178(2) wrote: Thu Aug 03, 2023 10:31 pm Talk to me more about your hausmann gearsets for the getrag
Gearset... only one was ever made. I consulted with a dude on Pfiffle to have it done for his L67/282 Fiero that he took out for track days. IIRC Jncomutt assembled the transmission once Houseman delivered the parts. Pfiffle dude ended up having problems with the input shaft and sold the entire setup to me for ~$0.10/$1.00. He decided he'd had enough crawling around under Fieros and bought a 996 Porsche to take to track days. Then he had an IMS bearing failure...

Here are pics of the output gears: https://realfierotech.com/viewtopic.php ... 08#p152208

It's a custom 1/2 set. The ratios are 2.50/1.85.

The Getrag 1st output gear was friction welded from two pieces of steel, one with the synchro interface/dogs and one with the gear teeth. The teeth are "undercut" so the shift collar actually fits inside the tooth root. Houseman said there's no tooling on Earth that can make that out of one piece of steel. He had to machine off the teeth from the Getrag output gears, make new teeth on rings and then weld those onto the OE synchro hubs. That operation went fine, but the smaller diameter 1st output required mods to the 1-2 shift collar. Getting those right took a couple of tries.

On the input side, in an effort to save money, we modified the 282 input shaft by machining off the integral teeth for 1st & 2nd, then making a cluster gear to press on. However, at some point that got screwed up. The input shaft was turned down to the diameter of the input bearing race for the entire length of the cluster gear, then the original diameter was left alone for the rest of the shaft. This created a large step in the shaft diameter, which creates a stress riser. While the engineering types say they specified a radius at the root of that cut, and there is a corresponding chamfer on the cluster gear, the radius did not make it onto the final modified part. The cluster gear was installed and the trans assembled. It ran great and Rick really liked the ratios... then it failed and he had a box with only 1st and 2nd. Disassembly showed that the input shaft sheared off at the stepped diameter.

In looking at the cluster, an unmodified input shaft and all the relevant dimensions, I see how to modify the cluster gear and the input shaft to avoid that problem... I just need to spend some time coming up with the exact dimensions and tolerances necessary to do it so that the press/shrink fit is tight enough to transmit the torque it needs to transmit.

To do it again, I'd just go straight to having the entire input shaft made, since that's a lot safer.
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Shaun41178(2)
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Re: Saab '03-'04 6 speed ratios & RPO

Post by Shaun41178(2) »

I remember that being done a while back. I must have forgotten that it broke too. Cool you ended up with it.
FieroWanaBe1
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Re: Saab '03-'04 6 speed ratios & RPO

Post by FieroWanaBe1 »

https://www.ebay.com/itm/354796011976?m ... media=COPY

This listing is for a 2006 SAAB 9-3 2.8T motor and Transmission.
it Appears this has an F40 trans.
Its hard to find data on the ratios used with the 2.8T engine when paired with a manual.
But it may have MT2 gearing with the 9-3 Aero's:
https://www.automobile-catalog.com/auta ... #gsc.tab=0
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Re: Saab '03-'04 6 speed ratios & RPO

Post by The Dark Side of Will »

I thought I'd read a long time ago that all the Saab V6 boxes were MU9. For 2009, the ratios are listed as MU9 in road tests. I have a '09 HFV6 box, but I don't think I've checked the ratios mechanically
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Re: Saab '03-'04 6 speed ratios & RPO

Post by FieroWanaBe1 »

I dug up my parts stash and though it would be interesting the show the differences between the SAAB 9-3 F40 and the G6 F40.
No speed pickup, and the shifter is very different.
Here is the 9-3 Aero Transaxle:
SAAB F40.jpg
SAAB F40.jpg (193.57 KiB) Viewed 2443 times
And the '07 and '06 G6 Transaxle:
G6 F40S.jpg
G6 F40S.jpg (215.43 KiB) Viewed 2443 times
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Re: Saab '03-'04 6 speed ratios & RPO

Post by The Dark Side of Will »

Your have FOUR F40's? :good: And I thought I was a hoarder with three! %) Or is that one in the lower right a Muncie?
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Re: Saab '03-'04 6 speed ratios & RPO

Post by FieroWanaBe1 »

The lower right transmission is a broken V6 Muncie.

I have 3 F40s, 1 '07 G6, 1 '06 NOS G6, and 1 '03 9-3 Aero.

I have a 2 84 Perf Muncies, 1 disassembled in a box and 1 crusty low mile unit.
I have 2 V6 Muncies, 1 with a broken shifter shaft, 1 working with a broken nut in the case
and I have 1 high mileage 87 Getrag.

That's my transmission collection.
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Re: Saab '03-'04 6 speed ratios & RPO

Post by The Dark Side of Will »

FieroWanaBe1 wrote: Fri Sep 29, 2023 10:35 am The lower right transmission is a broken V6 Muncie.

I have 3 F40s, 1 '07 G6, 1 '06 NOS G6, and 1 '03 9-3 Aero.
I have a '03 9-3, '07 G6 and '09 9-3 (w/ high feature V6 pattern)

Also a metric pattern F23 and a 3.63 F23

And a bunch of (10? 12?) 282s from all different applications.
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