I will refer you to the Haynes manual or the SAAB WIS for transmission removal.  A very quick flyby of this procedure goes something like this:  remove the wheels and loosen the axle nuts, remove the front exhaust system, separate the ball joints and drop the subframe, drain the transmission oil, remove the axles, disconnect the linkage and clutch cable, support the engine with a hoist and the transmission with a jack, remove the bell housing bolts, separate the transmission from the engine and remove the transmission from the car. 

With the transmission out, remove the 6 bolts securing the pressure plate (12 mm) and remove the pressure plate.  Remove the 8 bolts securing the flywheel (16 mm) and remove the flywheel.  Clean the flywheel and inspect it.  if you find signs of wear (glazing, crazing, cracking of the surface, etc) take the flywheel to a machine shop and have it resurfaced.  This costs me $30 locally.  When the flywheel comes back, it'll look like this:

Clean the surface of the flywheel with lacquer thinner and install on the crankshaft (it can only be installed one way; there's an alignment dowel).  Place Loctite blue on the bolt threads and install each.  Torque bolts to 59 ft-lbs in a criss-cross manner. 

With the flywheel in place, install the pressure plate.  I'm using Sach's replacement clutch kit and an alignment rod.  Install the 6 bolts, with Loctite blue, and torque to 16 ft-lbs. 

With the clutch and flywheel installed and secured, recondition the transmission.  I began with a thorough bath using Castrol's degreaser, followed by a coat of Duplicolor's Cast Coat Aluminum engine enamel.  I then replaced the differential seals and o-rings, installed a new shifter-shaft seal, and replaced the throw out bearing sleeve (and trans input shaft seal).  The input shaft seal replacement required me to weld-out the bolts.  When you replace this, be careful and heat the bolts to ease removal.  I installed the new throwout bearing and lubricated it with Mobil1 Synthetic High-temp disc brake grease (I used this on the 900SE 18 months ago and it still feels great, so I figure . . . ).  Here's the transmission after much work. 

The bushings, seal, throwout sleeve and throwout bearing were all renewed:

Since I'm using MTF0063 in the transmission, I installed the updated fill plug and added a label reading "Use SAAB MTF0064 oil only".  Additionally, since I'm using the revised shift linkage, I removed the stub on the rear mount that used to support the original linkage:

The transmission is ready to install in the vehicle.  To begin, I lubricated the shaft splines with synthetic grease.

More to come:  03/18/07

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