TECHNICAL SERVICE BULLETIN
Bulletin Nbr: 440-2497
Date:...........Oktober 2004
Market: all

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
km/h
M02-03
4 Sudden down shifting without reason with cold gearbox and
at low speed
M02-03
5 Gear slips in Lock-up mode M02-03
6 Engine speed increases during shifting 2-3 after long periods
of driving in top gear and then lowering speed to below 20
km/h, accelerating again and shifting up to 3rd gear.
M02-03
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
cover for brake B4
a) Check the servo cover, replace
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
housing valves
(SLS, SLT).
Replace valve housing with a
modified one (part no. 5449780)
9-5 (9600) -
Transmission -
Automatic Transmission
-
Adjustment/Replacement
- Valve housing
3 Error in TCM
software.
Update software in TCM.
(Download from IRIS)
4 Problem with speed
sensor, normally for
output speed.
Replace speed sensor
5 A bushing may have
moved and blocked
the oilways.
a) Check the transmission fluid
level and quality as well as that
the oil cooler hoses have
unhindered flow.
b) Check if a diagnostic trouble
code has been detected. Clear
the diagnostic trouble code and
test drive the car.
c) If the diagnostic trouble code
returns, replace the gearbox.
d) If the fault does not reappear,
return the car to the customer.
9-5 (9600) -
Transmission -
Automatic Transmission
-
Adjustment/Replacement
- Complete automatic
transmission or -
Automatic Transmission,
fluid level
6 Error in TCM
software.
a) Check the transmission fluid
level and quality.
b) Update software in TCM.
(Download from IRIS) M04 has
modified valve housing and new
software. Perform adaptation of
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.
9-5 (9600) -
Transmission -
Automatic Transmission
-
Adjustment/Replacement
- Automatic
Transmission, fluid level
7 This is a concept
selection for 5-
speed automatic
transmission.
None
8 Invalid adaptation. a) Compare the gearbox serial
number and the software ID
number and make sure that they
correspond.
b) Clear the adaptation values
and perform adaptation,
resetting. If the procedures do
not help and the customer
complaints continue, replace the gearbox.
9-5 (9600) -
Transmission -
Automatic Transmission
-
Adjustment/Replacement
- Adaptation, resetting
9 Electrical fault a) Read the value for the
temperature sensor when the car
is cold. Check that the value
corresponds with the ambient
temperature.
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
9-5 (9600) -
Transmission -
Automatic Transmission
- Technical data -
Transmission fluid
temperature sensor
10 Noise a) Determine under which
conditions the noise occurs (gear
position, speed, accelerator pedal
position, fluid temperature)
b) Contact the importer /ETAC for
help. Check whether the noise is
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.
9-5 (9600) -
Transmission -
Automatic Transmission
-
Adjustment/Replacement
- Complete automatic
transmission
11 Diagnostic trouble
codes
a) Read out the diagnostic
trouble codes, clear them and
test drive the car.
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.
9-5 (9600) -
Transmission -
Automatic Transmission
- Component location
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
drive the car.
b) If leakage returns, photograph
the area and mark the area with
a pen.
c) Rectify the leak or replace the
gearbox if necessary. Enclose the
completed checklist and the
photograph when the gearbox is
returned.
9-5 (9600) -
Transmission -
Automatic Transmission
-
Adjustment/Replacement
- Complete automatic
transmission