Saab '03-'04 6 speed ratios & RPO

[FieroWanaBe1]

Forgot about the reverse riding on 1st.

I need to discuss synchromesh, since they build dog-box transmissions currently, that will take some effort.
For a new input shaft with spline, 2 gears, hardened, I would expect $1500-$2000
For 3 output gears maybe $500 ea, add synchro cuts, another +$250
That may be a total of $4000

I wouldn't attempt this unless at least 5 people agree to move forward and make a 33% deposit.

The lower cost option, Keep the 2.04 second,
Recut the input shaft to take a spline on 1st gear, 2.7:1-3.0:1 Keeps the drop from .76-.68 (much better than the .54)
The would probably run closer to $2500 if 5 people sign up and send out a input shaft to be modified.
Any other vendor I know would be much more expensive to deal with, and less willing to do things that aren't to an established industry standard.

[The Dark Side of Will]

Forgot about the reverse riding on 1st.

I need to discuss synchromesh, since they build dog-box transmissions currently, that will take some effort.
For a new input shaft with spline, 2 gears, hardened, I would expect $1500-$2000
For 3 output gears maybe $500 ea, add synchro cuts, another +$250
That may be a total of $4000

I wouldn't attempt this unless at least 5 people agree to move forward and make a 33% deposit.

The lower cost option, Keep the 2.04 second,
Recut the input shaft to take a spline on 1st gear, 2.7:1-3.0:1 Keeps the drop from .76-.68 (much better than the .54)
The would probably run closer to $2500 if 5 people sign up and send out a input shaft to be modified.
Any other vendor I know would be much more expensive to deal with, and less willing to do things that aren't to an established industry standard.

Ooops... didn't see that you'd posted this, and edited my prior post.

[FieroWanaBe1]

F40trans__54809__64618.1355861725.1280.1280.jpg (121.58 KiB) Viewed 5877 times

The first input gear will get larger, and the whole shaft will have to be made to accommodate that. I can tell you from experience in advising someone who did this for the 282 that growing the first input gear will have to take clearance to the 1-2 shift fork into account.
The first output gear will get smaller. Packaging things that get smaller is usually easy, but on the output side, you need to keep the synchronizer interface in mind. In the 282, the first output gear is a friction welded assembly, because the synchronizer interface is recessed INSIDE the gear teeth. To make the aforementioned gearset, Houseman machined off the stock teeth, then pressed and welded on their gear. The shift collar then had to be machined for clearance due to the space inside the recess being smaller because the gear diameter was smaller.

It looks like the f40 is a little different. From the pictures I have seen the synchro interface in on the face of the 1st output gear and reverse output gear, not recessed behind the face.
But the 1st gear width will be limited in order to clear the 2 sets of shift forks.

Can they cut the synchro interfaces? That's not just he synchro dogs/splines, but also the conical interface to the blocker ring.

That has to be determined still, how well they can duplicate what the F40 has.

1st and reverse may be large enough to remove cut and reused the F40 synchro splines/cones from their gears and weld them to new gears.

I have 3 transmissions here, if 4 more people are interested in something, either sending their trans in, or buying one outright, be it a new 1st alone, or a 1-2 set I will try to make this a real and serious conversation with a vendor.

[The Dark Side of Will]

F40trans__54809__64618.1355861725.1280.1280.jpg

I have 3 transmissions here, if 4 more people are interested in something, either sending their trans in, or buying one outright, be it a new 1st alone, or a 1-2 set I will try to make this a real and serious conversation with a vendor.

I have 2, and will be acquiring a third sometime in the next couple of months. I have to tear two down to build the one I want, so I'd be happy to send off internal parts for inspection/modification.

I am interested in the 2.50/1.85 dual replacement option, but will settle for the ~3.0 first option if you can only get buyers for that one.

Now if you have a lead on a 0.62 sixth gear set...

[FieroWanaBe1]

Now if you have a lead on a 0.62 sixth gear set...

I have a MT2, A SAAB 3.91 Box, and what's supposed to be a 07 MU9 Box.
My desired build of factory ratios would be:
FD: 3.91, 1st:3.77, 2nd:2.04, 3rd:1.37, 4th:1.05, 5th:.085, 6th:.062

Leaving me with these boxes:
FD: 3.55, 1st:3.77, 2nd:2.04, 3rd:1.32, 4th:0.95, 5th:0.75, 6th:.62
and
FD: 3.55, 1st:3.77, 2nd:2.04, 3rd:1.32, 4th:0.95, 5th:075, 6th:0.72 - essentially a box with two 5th gears.

All the pro MK6 transmissions have a 3.77 1st and 2.04 second. so any box before the Regal should be able to get an upgraded 1st.

Any box would be able to get an upgraded 1-2, if they can handle whatever the input spline becomes. that may be changed to accommodate better available clutch hubs.

[The Dark Side of Will]

Now if you have a lead on a 0.62 sixth gear set...

I have a MT2, A SAAB 3.91 Box, and what's supposed to be a 07 MU9 Box.
My desired build of factory ratios would be:
FD: 3.91, 1st:3.77, 2nd:2.04, 3rd:1.37, 4th:1.05, 5th:.085, 6th:.062

Leaving me with these boxes:
FD: 3.55, 1st:3.77, 2nd:2.04, 3rd:1.32, 4th:0.95, 5th:0.75, 6th:.62
and
FD: 3.55, 1st:3.77, 2nd:2.04, 3rd:1.32, 4th:0.95, 5th:075, 6th:0.72 - essentially a box with two 5th gears.

All the pro MK6 transmissions have a 3.77 1st and 2.04 second. so any box before the Regal should be able to get an upgraded 1st.

Any box would be able to get an upgraded 1-2, if they can handle whatever the input spline becomes. that may be changed to accommodate better available clutch hubs.

I have '03 Saab MT2 with 3.91 and '08 Saab MU9 with HFV6 bellhousing. I am currently looking for '07 Pontiac MU9 with Metric bellhousing.
My goal is the same as yours: MU9 1-5 with MT2 6th, 3.91 final and Metric bellhousing. This is the box that would get the modified gears.

My '08 MU9 box will go with LLT or LFX into the Storm Trooper. I'm interested in getting a 0.62 sixth for that box, but I'm not wild about buying an entire transmission to have that gear pair. Are you willing to sell your "extra" 0.62 sixth?

[FieroWanaBe1]

Ill need to debate that. It would hurt my ability to sell that box off.

[The Dark Side of Will]

Ill need to debate that. It would hurt my ability to sell that box off.

You can have my 0.72...

[The Dark Side of Will]

I remembered this could go in this thread as well:

Also, I snagged a 3.91 F40 from a '03-'04 Saab late last year... it's been kicking around the back of my van in a tote for months and months. I finally verified the ratios and dropped it into "storage" next to my '09 Saab F40 with High Feature V6 bellhousing. My aim is to snag an '07 G6 F40 and merge it with the 3.91 F40 to build The Mule's eventual transmission. The '09 Saab trans will get married up to a LLT of LFX to be ready for... something. It has MU9 gearing, so I'd love to get an MT2 0.62 sixth for it.

I was surprised to find that it looks like this box has a Torsen or similar diff.

Circling back for a sec...
This thread mentions a factory Saab helical LSD... so apparently I lucked out in that this transmission has one. Sweeeeeet!

https://www.uksaabs.co.uk/UKS/viewtopic ... 94#p929894

[The Dark Side of Will]

I think this is fitting here.

https://www.short-shifters.com/v-shift- ... r-kit.html

Short throw linkage for the F40 transmission.

That's pretty cool... It's been posted here for a while, but I'm not sure I remember looking at it before.

[The Dark Side of Will]

Thanks to help from Howard and Shaun, I got my hands on a 2007 Pontiac G6 MU9 transmission. The 2006 G6's have MT2 transmissions, while the 2007's have MU9s... Pretty weird, but that's the way it is.

The unit came from a junk yard in FL. The guy I talked to at the yard said that the fluid had metal shavings in it, so he couldn't sell it to me as a working transmission. I offered him a core price for it, and he went for that. After many shenanigans with freight shipping, it arrived in VA last week.

A long time ago I disassembled a Quad4 Getrag previously owned by someone who could not leave a stoplight without doing a peg leg burnout. The shifted gears and ring/pinion were ok, but one thrust washer between the side gear and the diff carrier was ground to shrapnel and the diff carrier was galled and ruined. I @$$umed that this G6 gearbox would be similar.

Before I disassembled the transmission, I took a look at the CV joint cup that came with it. There are witness marks where the shaft portion had been spinning in the diff carrier... a few burnouts were done.


I read the disassembly instructions a long time ago. The shift turret came right out. I removed all the case bolts, but the halves wouldn't come apart. I finally realized I needed to look inside the bellhousing and found the last damn bolt inside there. Of course all the others are E12 head 8mm bolts, and that one is an E14 10mm. WTF?

Once I had that out, it came apart easily.


There was a subtle ring of ferrous goo around the magnet in the VSS. There's almost nothing on the trash magnet.



Junkyard bro sold me a good gearbox for a core price... Kinda makes up for the PITA of getting it shipped here.





Aside from verifying the internal condition of the unit, one of the things I wanted to see was how much room is available to grow the reverse output gear. There is PLENTY of space between reverse output and first input. The closest thing to the reverse output gear is the reverse shift fork, which has at least 1/4" of clearance, probably more, and can be relieved if necessary since it's only for reverse.

I'm looking at that for the possibility of having a custom 1/2/R set cut. In order to do that, the first input gear has to grow. The first output gear has to shrink. However, because the reverse output gear is driven by the first output gear, the reverse output gear has to grow as well. To go from 3.77 to 2.50, first input would have to grow from 15.9mm to 21.7mm pitch radius, or about 5.8mm on the radius. The first output gear would shrink by the same amount and the reverse output gear would grow by the same amount. It *looks like* there's enough room to do that without modifying anything else.

I'll probably need to disassemble all three of my F40's in order to have a few sets of parts to send to Houseman to duplicate.

[FieroWanaBe1]

Now if you have a lead on a 0.62 sixth gear set...

https://www.amazon.com/ACDelco-12787428 ... B00B4L0RX4

ACDelco GM Original Equipment 12787428 Manual Transmission 6th Gear

[eHoward]

Glad it worked out. I was a little concerned about your shipper.

[The Dark Side of Will]

Now if you have a lead on a 0.62 sixth gear set...

https://www.amazon.com/ACDelco-12787428 ... B00B4L0RX4

ACDelco GM Original Equipment 12787428 Manual Transmission 6th Gear

I have that one

If you can find the other side such that I can actually buy it, I'll give you a finder's fee.

[The Dark Side of Will]

Glad it worked out. I was a little concerned about your shipper.

Yeah, that was a weird experience, but eventually it arrived ok.

[Emc209i]

Needed a little shaft rattle in your life, Will?

[FieroWanaBe1]

I remembered this could go in this thread as well:

Also, I snagged a 3.91 F40 from a '03-'04 Saab late last year... it's been kicking around the back of my van in a tote for months and months. I finally verified the ratios and dropped it into "storage" next to my '09 Saab F40 with High Feature V6 bellhousing. My aim is to snag an '07 G6 F40 and merge it with the 3.91 F40 to build The Mule's eventual transmission. The '09 Saab trans will get married up to a LLT of LFX to be ready for... something. It has MU9 gearing, so I'd love to get an MT2 0.62 sixth for it.

I was surprised to find that it looks like this box has a Torsen or similar diff.

Circling back for a sec...
This thread mentions a factory Saab helical LSD... so apparently I lucked out in that this transmission has one. Sweeeeeet!

https://www.uksaabs.co.uk/UKS/viewtopic ... 94#p929894

My SAAB box has the same view into the diff housing. It must have been common with the F40 option.

[The Dark Side of Will]

Needed a little shaft rattle in your life, Will?

I need a lot, apparently, because I own three of these things right now.
Getrags sure don't have enough!

[The Dark Side of Will]

Forgot about the reverse riding on 1st.

I need to discuss synchromesh, since they build dog-box transmissions currently, that will take some effort.
For a new input shaft with spline, 2 gears, hardened, I would expect $1500-$2000
For 3 output gears maybe $500 ea, add synchro cuts, another +$250
That may be a total of $4000

I wouldn't attempt this unless at least 5 people agree to move forward and make a 33% deposit.

The lower cost option, Keep the 2.04 second,
Recut the input shaft to take a spline on 1st gear, 2.7:1-3.0:1 Keeps the drop from .76-.68 (much better than the .54)
The would probably run closer to $2500 if 5 people sign up and send out a input shaft to be modified.
Any other vendor I know would be much more expensive to deal with, and less willing to do things that aren't to an established industry standard.

I was looking at Houseman for creating/modifying the gearsets, since they were the ones who did it on the 282 set I consulted on (and now possess).

If I *really* wanted to go crazy, I'd have a gearset made that swaps 1/2 with 3/4. The upper output shaft center distance from the input shaft is significantly larger than the lower output shaft center distance. I've read somewhere that the lower output shaft center is 76mm, which is a familiar number. Swapping 1st to the larger shaft center output shaft would significantly increase the pitch radius of the 1st input gear, making the 1st gear set considerably stronger. I have NOT done the arithmetic to see how much larger the 1st output would be, or if there would be room for it inside the case or clearance to the shift rails.

[Shaun41178(2)]

Talk to me more about your hausmann gearsets for the getrag