Shaver's '94 vert [Archive] - SaabCentral Forums

: Shaver's '94 vert

31st January 2007, 10:36 PM
Well i didnt by this car as a project car but it was my first saab and I will admit I'm addicted!

I am the second owner of this car and bought it in 2002 with 140,000 miles. The car originated from canada. The car now resides with me in florida.
The car was problem free and 100% original until 8 months ago when the tranny decided to lose first gear.

With many modifications in mind to improve performance (but not too radical) I began my search for a transmission that could handle the power.

To my great surprise I found a sought after chillcast 4-speed on ebay and purchased it only to have my dreams crushed when u.p.s. told me they damaged it in shipping with a forklift...:(

A few months later I found another chillcast...This one freshly rebuilt!!!
After recieving the new tranny i began dissambly of the old one. I took a little different approach by leaving the motor in the engine bay and dropping the transmission out the bottom. This limitted the amount of vacuum/electric lines i had to remove/unplug.

During the waiting period for the new transmission I picked up some performance goodies which included:
7lb aluminum flywheel
new clutch kit (pressure plate/slave/clutch disk/line)
s.d. red series apc
s.d. red series eprom
s.d. red series injectors
k&n drop in filter

I also picked up new ball joints/tie rod ends/trans gaskets/dist. cap rotor
and all the general maintenance stuff like plugs/wires/etc.....

The car currently is in my garage waiting for my new license plate/insurance.
I have only driven it aroun my parking lot testing the transmission but it feels great! This was my first tranny swap ever on a saab ad i must say it went smooth!

There were a few alterations necessary to make it fit and i will try to post pictures to illustrate the differences.

31st January 2007, 10:38 PM
This is how the saab looked when i brought it to Florida. (after a bath of course ;)

31st January 2007, 10:41 PM
I will post a link to the install pics soon for those interested i do not want to have to post them all here and bog down the site loading images ;).

1st February 2007, 02:27 AM
Sweet Jeff, I'll be looking forward to seeing your progress and pictures! :)

1st February 2007, 07:42 AM
Here are some links to the teardown/install

New 4-Speed Transmission!!! (
Flywheel (
Engine Hoist (
Motor Mounts
Shifter housing

more to come soon...

1st February 2007, 07:18 PM
Hey jeff

just curious, hows the 4 speed gonna affect the car gearing -wise?

Will it bring your top speed down by much? If it does will it mean having to apply much more revs to cruise along at say 70mph over the 5 speed box?

I've been contemplating putting a 4 speed box in my 99 when the new engine goes in just because the strength of the box and quality of the shift is supposed to be that much better, but was wondering if it would mean that revs become unbearably high and I end up "running out of gears" on the motorway and such...

very nice car by the way:D

2nd February 2007, 07:13 AM

In all honesty i dont know...
I havent had it on the road yet to test it out. 1st gear is definately a lot longer as I can hit about 25mph but in theory it will probobly max out at around 120.
Redline will come sooner but how much sooner depends on what final drive is in the box I have. I still have the final drive from my 5-speed that could be swapped to improve the gearing as well.

Fo me gearing wasnt too much of an issue as this is just a sunday driver and the posted speed limit rarely gets above 60mph here. :roll:

I will post some figures when i get the car licensed and back out on the road.
Also I am running slightly lower profile tires than normal too so that may have a negative affect. (incorrect tires installed by firestone.....but thats another story)

10th February 2007, 11:42 PM
Today's project...

12th February 2007, 12:45 AM
Man you sure like your red;)

I have to say that is a stunning looking vert.

7th March 2007, 11:13 PM
I finally got around to installing the sd red series apc and the bigger injectors.
I took apart the old apc and compared it to the existing stock '94 one. THere were too many differences to count...I was expecting a resistor here or there to be different but wow they were quite different.

Its off to the junkyard this weekend to get a new fuel rail as after following the bentleys directions I bent the fuel rail slightly out of proportion and i can not install the retaining clips...grrrrr.

Next step after the fuel rail is to locate the eprom and swap out the chips.

10th April 2007, 11:53 PM
Well I totally forgot I had started a project thread for this.
Updates include:
-Installation of eprom, new fuel rail, injectors, apc,

The car has finally been licensed an put back on the road. Its an absolute menace!:D The 4-speed has obnoxious acceleration I LOVE IT!

I had to replace all the stock hose clamps as the screws began popping out for some reason. But the car did set for a year.

3,000rpm is still the sweetspot still but the alum flywheel def makes it get there a lot faster!

Although not meant for highway speeds. At 55mph I am 3,000rpm at least I will never get passed...

I will be swapping out the primary gearing to type 6-primaries this weekend. I removed those from the original 5-speed. I am told this will make the highway more managable.

Forget driving in the rain too as its just wheelspin everywhere when the turbo kicks in!

edit-I now have a shiny freshly painted valve cover with NO LEAKS!!!! hooray!

10th April 2007, 11:56 PM

10th April 2007, 11:59 PM
more pics...

11th April 2007, 07:52 AM
Do you feel its easy to stall the engine with the lighter flywheel?

I don't know where I heard:lol:

11th April 2007, 08:05 AM
Yes it does require a bit more clutch work off the line. Most noticeable at stoplights where there is an incline. Its nothing really significat though. With A five speed with shorter first gear I dont think it would be an issue at all but the 4-speed has a much much taller first gear.

12th April 2007, 12:44 PM
I've developed a slight "clunking" noise in the front drivers side. I will put it up on stands tonight and find out what I forgot to tighten..:nono;

12th April 2007, 10:40 PM
Sooooo, I got under the car today and found that my driver's side caliper was loose...
I tightened that up and added a few ftlbs of torque to the suspension parts and I will take it for a drive in the a.m.

Anyone have any recommendations for control arm and shock bushings or are oem sufficient??

13th April 2007, 12:14 AM
OEM rubbers are fine, its just some guys are anal and want the stiffest ride possible:lol:

Your car looks amazing, I'm really jealous to, my vert as been in dry storage for almost 4 years now! no almost 5! fook sake!

21st July 2007, 04:24 PM
Ok its been too long since an update so here goes:

New rear brake rotors, pads, custom ss braided lines, New front rotors and pads. Full system bleed, replaced brake fluid, Replaced majority of the vacuum hoses, added Forge Atmospheric dump valve (BOV) currently having issues plugging the recirc lines though...
Anyhow the car is coming along great, unfortunately the brakes I replaced were not the crossed drilled rotors I ordered (no longer avail) and updon starting the snstallation I discovered it didnt even need to be done :roll:. The breaks were in excellent shape I was just getting some sqeeking from a bent dustplate....:p

21st July 2007, 04:26 PM
another pic,

21st July 2007, 04:26 PM
Shadow, get that vert out and enjoy the summer!

25th February 2008, 12:24 PM
I admit it...I've neglected to update this in quite some time...
It would be much nicer if we could edit existing posts, then we could all keep a better mod list...

Anyhow the car is my daily driver and I have had minimal issues lately.

The most recent mods include 3" exhaust (from the stock wrapped downpipe back) into a 5o series flowmaster. (2.5" over the rear axle back to 3")

I installed a forge atmo dump valve. This required a new steel mandral bent intercooler pipe (So I could weld the bung on)

I also had some fueling issues which turned out be a failed fuel pump. I purched a 75glp IIRC unit from SD along with their 3 bar fpr. I ended up replacing the supply line fitting along with a small section of the fuel line due to it being damage during the fuel pump removal/install.

I ordered a Short throw shifter through this sites group buy (Thanks IronJoe) and will be installing that when it arrives.

The car runs excellent now with the exception of some idling issues I am still trying to sort out.

Also picked up some new ngk plugs (still waiting on wires)

I had a small water leak from the turbo water supply line and though I was having headgasket problems. (The turbo was evaporating the coolant before it could leave any spots on the ground) After replacing the line I have some air pockets in the system so I picked up a ss thermostat and the necessary gaskets so I can do a proper flush this weekend.

5th March 2008, 05:13 PM
Well I neglected the thermostat to much and melted my optima battery lol. I installed the new thermostat, bled the coolant system and fixed a bad connection to the fan switch and the car appears to be running a fair bit cooler now.

This weekend I am going to make a heatshield for the battery to avoid another meltdown...

5th March 2008, 05:16 PM
You should move your battery. Next to the exhaust is an awful place to have it, heat shield or not.

17th March 2008, 06:06 PM
Thanks IronJoe, Its something I've been meaning to do and now that I've moved and have a larger garage I have a bit more incentive ;).
It turns out some moron who changed out the tranmission hooked up the electric fans improperly and thats what contributed to the battery melting. (ok it was me ;oops: ). Anyhow I finally unhooked the forge atmo valve (left it installed) to correct the terrible idling problems. I am much more confident in driving the car in heavy traffic now.

The next project will probobly be new tires (The correct size this time) and a proper alignment.

But the stereo might come first as my cd player/eq and antenna died around the same time and I now have a 45minute commute with the loudest exhaust note ever due to the high rpms of the 4 speed. I still have the primaries from my 5-speed and I plan on swapping them out as soon as time permits.

I forgot to mention I installed new plugs wire cap and rotor the other day as the others were toast (probobly due to the atmo valve)

14th April 2008, 06:57 PM
Woohoo an update!

I installed the short shifter. (It was a breeze and a drastic improovement.)
Installed a new set of Yokahama's (Spelling?) (195 60 r15)
Finally having the correct size tire brings back the excellent handling.
Of course after buying the tires it appears I will be in need of a headgasket soon. (go figure :roll: ) I am losing a considerable amount of coolant. Luckily its not present in the oil.

After getting a quote of close to $2000 US for the job (mandatory $300 valve job to get warranty) i have decided to take this project on myself. (This is always how it starts :p )

I am hoping to put this off until after the 20th as this would be the 3rd year in a row I've missed the Tampa meet due to car issues!!!

22nd April 2008, 12:24 PM
Well I missed the Tampa meet anyway because it was cancelled without warning...
My head gasket kit arrived over the weekend along with my new car.

I am afraid I will be saying goodbye to the saab world but I will continue this thread as I refuse to give up the saab until the project is complete.

The remaining items:
Head gasket (and all the bits necessary for the fix)
New canvas top
Stereo - (currently has a non functioning cd player/eq)
power antenna - (broken)
I may do some new leather depending on the price.
I have the replacement for the drivers door pull as the interior one had split.

I will most likely try to get rid of the car before I realize how much I like them.

The new car is an 06 crossfire. I dont know much about them but they remind me of certain "quirky" cars...

22nd April 2008, 02:14 PM
Don't like the sound of that jeff, like your car!

But PM when done and/or before you sell it, please...?


22nd April 2008, 05:56 PM
But PM when done and/or before you sell it, please...?

Sure thing. I'm planning on doing the engine/head work this weekend but I may put off the top for a bit. I am more motivated than ever now becaus I need the garage space. the new car has been sitting outside lol...

29th April 2008, 07:36 AM

I pulled the head off and the inspection went well. The cylinder walls were nice and smooth with no sign of damage. I did not that the exhaust manifold appeared to be leaking from its gasket between the center cylinders. Everything went really smooth except for those two bugger of a bolts underneath the head near the timing shain cover. You have to be gumby to get your hands down there...

I will post up some pictures as soon as the internet is up and running at the new place.

12th May 2008, 12:27 PM
Finally some pictures! These are the new yokohama (spelling) tires I got two days before The head gasket issues...:roll:

12th May 2008, 12:31 PM
Some additional pics I hadnt previously taken off the camera. This is the short shifter purchased through the saab central group buy. Along with the other two factory styles.
Here is the recirc and atmo valves I have simultaneously installed. You can see the stock plastic unit that I removed.

12th May 2008, 12:32 PM
There is a whole bunch more photos I will not bother filling this thread with but for those as bored as I amm...

28th September 2008, 08:03 PM
Well the head work is complete, I put the finishing touches on the small items and plastic bits today so the car is now back in running order. I need to update the registration and get some insurance on it before I can really test it out but I've been making some quick runs up and down the driveway and it seams to be sorted fairly well with no leaks but I haven't hit boost yet.

I did get a chance to wax and clean the car so some updated pics are below:

I'm still debating on how much additional work I will do or if the car will be sold to fund a new project. I guess I will wait it out until after the saab meet this weekend.

5th October 2008, 04:26 PM
Changed the tranny oil and engine oil today as well as the 02 sensor. I snapped an exhaust flange bolt in the process but I got a new set of drill bits out of the deal :). After tightening up a few misc. items I took the car for the first drive since the head gasket replacement. I got a good 45 min of driving in before the rain came and I had to call it night but so far no leaks, no smoke, and a much better idle. (probobly thanks to the new O2)

Remaining items I need to address before the meet tuesday is a coolant flush,timing set, and a good wax and polish.

Items that need to be addressed for the project to be complete:
New top
New leather
New paint (hood only)
Shocks (maybe they are still pretty good)
Battery relocated to pass side (under CAI)
all of this is pending I do not sell the car first of course

5th October 2008, 06:41 PM
Beautiful car Jeff! I hope I can get my black vert so shiny :lol:

6th October 2008, 05:03 PM

If you don't already have a wax preference I highly recommend the turtle wax "ICE" line. This was the first time I had used it before and the results were amazing. I bought it based on the aero x image alone ;). Too bad the wax is phenominal but the interior detailer is crap.

7th October 2008, 12:26 AM
I'll try... in 6 months when the summer is again :lol:

8th March 2010, 09:31 PM
Its been awhile so I suppose I can post an update:
Relocated battery to drivers side.
Removed the rear axle and replaced bushing shocks some lines and whatnots. Cleaned and painted what needed it.

8th March 2010, 09:35 PM
Looks like the new yokohamas might have to go away...
Only a few hundred miles and I came across a set of super aeros and think they fit the car much better. They were full of the typical scuffs and curb rash so I am in the process of refinishing them. Currently everything has been smoothed out and coated with an acid self etching primer just waiting for some less humid warmer weather to finish them off:

8th March 2010, 09:40 PM
Here is some more photos (Custom exhasut I neglected to post earlier:

8th March 2010, 10:21 PM
I dug up a few more pics of the DP:

12th April 2010, 06:09 PM
More progress in preparation for a local car show. I realigned the bumpers, reworked the cai brackets, put lots of the shrouds/misc brackets I had neglected to put on since the trans swap. Spent the better part of a night cleaning and polishing which payed off as the car took first place in its class. Not a big turnout but thats ok ;)

31st July 2011, 10:33 AM
Following up:

I finished the new top install a while back, I just need to get around to taking more pictures. Everything went fairly smoothly and looks great. I just picked up another vert which is getting me back into completing this one also.

Time to start a new project thread ;ol;.

The to do list is almost complete, just really minor stuff now!

To do list:
Locate 4-speed oil dipstick and swap out the plastic tube for correct one
Correct radio gremlins
Swap new power antenna
Fresh plugs, wires, cap, rotor, pcv, etc
Reweld exhaust hangers, (somethings been rattling a bit)
Once the new tires are worn out install the super aeros
Maybe swap one of the tailights for a spare as it has a minor crack.
New front emblem on hood (faded)
Almost forgot, replace the battery

7th August 2011, 02:21 AM
Cool build you have going here. How is the gear box working out for you? I've had thoughts of finding a chilcast box from a 99 and switching things over as well. Does it handle power in the lower gears better?

7th August 2011, 07:28 PM
The chillcast box has held up great. The lower gears are much longer so downshifting to first and even crusing through a parking lot in first is fine. Unfortunately this is only a 4-speed so you have higher rpms when crusing on the expressway. Ideally I would like to keep the 4-speed and swap to a better final drive but no plans to change until other projects are finshed.