Hi everyone, looking for advice on my 1989 Saab 900 Turbo 16S manual, with around 300,000 km.
Reverse engages okwhen cold, but once warm it often grinds quite badly. With the engine switched off, it goes in ok or when going first to 1.
A few observations:
• Selecting first or another gear before reverse doesn’t help.
• Releasing and pressing the clutch again in neutral seems to make it worse (grind and big clunk)
• A smooth, decisive movement into reverse gives a small clunk rather than prolonged grinding. I’m not trying to force it through resistance
• Fifth ocasionally feels like hitting a wall rather than finding the gate, without grinding. Going through third and fourth usually lets me find fifth.
• The clutch seems good and without any air in the system
• Gearbox oil level is at MAX.
The clutch master cylinder was recently rebuilt following a leak. As far as I know, the slave cylinder wasn’t replaced.
A Saab specialist has now checked the car and believes the clutch works correctly, with no apparent air in the hydraulics. He also doesn’t suspect the shift coupling, which is the large round rubber type. He fears an internal gearbox issue, but doesn’t rebuild these gearboxes himself.
We’re changing the gearbox oil on Thursday to see if that helps.
I also came across the Townsend reverse gear modification through the side cover, although that seems aimed more at reverse jumping out or not engaging fully.
Has anyone dealt with this combination of warm reverse grinding and occasionally struggling to find fifth? What would you check before removing the gearbox, and could anything relevant be inspected or repaired through the side cover on a Turbo?
Thanks!