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the car is broken... gear shift? Linkage, resolved

 
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Hello oh wise Permies!

Yes, for those who remember my troubles, it's the 1996 SAAB 900

For a few weeks, the car has been acting up again. It has not been wanting to go into 1st or reverse for me. But if I turn it off, and place it in gear, it would start with no problem, and shift gears as it should. Until I stop at a light, and have to repeat.

Hunny was driving it and it got stuck in 2nd gear and would not shift out. He drove a number of miles home that way. We have it parked with the emergency brake on. It now has a free floating gear shift, that only moves between 1 and 2. But the car does not shift.

Here is where we replaced the clutch. I don't think it's the clutch?

Here are diagrams of everything to do with the transmission.

Here are some directions to try with the shifter. But some want it to be in 4th gear to be able to check these things?
https://photo.platonoff.com/Auto/20050404.Saab_NG900_Old_Style_Shifter_Linkage/?all
https://photo.platonoff.com/Auto/20050325.Saab_NG900_Shifter_Alignment/?all

Please help my brainstorm?
 
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Sounds like the linkages in the gear shift train are worn.
Sometimes there are plastic bushes that clip in to the holes.
I will check a manual and see, look at this Forum
https://www.saabcentral.com/threads/shift-linkage-5speed-manual-transmission.82347/

Part # 20 is the bush that wears out, that may be the problem. There are 2 of them.
Saab manual gear shift parts
 
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Just to clarify:  Clutch pedal is acting normal?  The only gear shift movement is moving from 1 to 2 now? You can get no movement sideways in the shift pattern?
I'm with John if this is the case. https://www.maptunparts.eu/pdf/63-Installation-guide-bushing-kit-for-shift-linkage.pdf
 
Joylynn Hardesty
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Thanks guys. Below is a link to video of the shifter moving. There is a slight play to the left and right that I missed yesterday. See video below.

https://youtube.com/shorts/appM4yKPfTc?feature=share

The directions page 4 a d 5 of Robert's link, include carefully welding a metal washer to something. There is no work aroundfor the welding?  Crap.
 
Joylynn Hardesty
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Oh, and yes the clutch pedal is working normally.
 
Joylynn Hardesty
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Okay, there's a contradiction in the above answers. John's bushing is plastic, for the stick shift. The instructions I downloaded are for replacement of metal bushings for the linkage. I think.

Thoughts?
 
John C Daley
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In many cars they are plastic, I stand corrected here because I was guessing, SAAB would be the same.
Sorry.
As for weld, there is not alternative, but you could take it somewhere on a push bike and get it welded for a cup of coffee!
Great fins Robert Ray.

If you videoed the movement of the shafts through the bushes ' mentioned in dispatches' you may see the wear.
 
Joylynn Hardesty
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Would this be the correct diagram?

Part #9 bushing is plastic, or nylon, whatever... now what?
 
Joylynn Hardesty
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Oh, the gear shift bushings are plastic. These are at the stick for shifting in John's diagram. Accessed inside the cab of the car.

On Robert's instructions, the metal bushings go on the linkage near the gear rod, accessed from under the car.

I think.
 
Robert Ray
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It's hard to pinpoint just where the linkage play is coming from without actually having hands on. The Saab transmission itself is pretty robust. From your description I'm still leaning towards the linkage. The many Youtube videos show how to set the transmission into a known gear with the use of a lock pin. Once you get to that point fiddle farting about you might be able to see where there is excessive play and pinpoint the linkage/bushing in question. Regardless you will at some point have to set the transmission into a known gear. If it were my Saab(sob) I would begin there, and wiggle things about.
 
Joylynn Hardesty
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To check the bushings on the gear shift, am I going to have to take out the full stick shift assembly? I found instructions, with pictures, but...

Also I have not found instructions on how to realign the stick shift to the innards, if I don't have the shifter in 4th gear when taking it apart. Per Roberts instructions of locking it in 4th gear with the allen keys....
 
Joylynn Hardesty
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It's pouring down rain, with flood warnings. I'm not working on it today, no garage here.

Youtube videos show how to set the transmission into a known gear with the use of a lock pin.


I'm concerned about this, I've found how to lock it in 4th. But, how do I line it up, if I  don't know what gear the shifter is in, in relation to the gear the transmission is in? I don't know yet if this is a problem. The shifter currently moves freely from 1 to 2.


Here's the online WIS book webpage for my model. The mechanic's book for repair.

Joylynn wrote:To check the bushings on the gear shift, am I going to have to take out the full stick shift assembly?


Yes, accordingto the WIS.
 
Robert Ray
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Mechanic work in the dirt let alone mud is never any fun.  The luxury of a lift or pit to comfortably work under a car makes it so much easier. My European mechanic friends say with your description sounds like a linkage issue, so that is where they would start. Getting the car into a known gear and observing the play, slack, movement of the linkage. I hope it is an easy affordable fix.
 
Joylynn Hardesty
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Referencing the text in the picture below, maybe the bushing itself performs the function that I imagine a bolt would accomplish?



So I definitely need bushings. Oddly enough, maybe I can remove and replace this thing without getting under the car.

These items were hanging out on a surface under the car. I do not know if they are related.



This is the bushing kit shown in Robert's download. This company is out of stock. I have not found them anywhere else. Any ideas? The linkage assembly for this car does not seem to be available.

Thoughts, ideas?

EDIT: The black round plastic or nylon thingy fits where a bushing should go. That is where we put it.
 
Joylynn Hardesty
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Per the company who makes them, the bushings will be back in stock next week. Whew.

There is still the question about the bolt vs bushing/washer combination. What keeps the black polygon from sliding off the shaft?
 
Robert Ray
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Excellent, at least it is an external fix and not something internal. You'll be a seasoned Saab technician soon.
 
Joylynn Hardesty
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So in this post, I mentioned that maybe a bolt was missing. There was no exploded diagram to consult.

Today, our most awesome neighbor asked why we had bricks chucked under the car. He took a peek, asked if we had any random bolts laying around. Of course! Who throws bolts away? He cobbled some nuts and washers together, and sent Hunny down the road in the car.

IT SHIFTS!

So we need to get an actual hard bolt in the next couple of days. This one is of soft metal and may get damaged soon. Did you hear? I  HAVE A CAR THAT RUNS!!!
 
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