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I use a Subaru Legacy plastic filler tube. Cut it down to size, grind a sleeve into one end so you can attach the two pieces together, then JB Weld. Cut at an angle such that the filler cap is horizontal; take into account the 45* angle of the block, and don't forget about hood clearance.
Drill a hole for the tube in the valve cover, and drill/tap the two holes. You can't see in the pic, but the tube protrudes beneath the mounting boss -- it's not a flush fit. You'll need to grind down the valve cover "stripes" for a good fit at the mounting surface. Alternatively, get a flat cover from a newer car.
I use 518 for a gasket -- it's not ideal (it's "moist" with oil, but no big drips/leaks). Do a DIY gasket with material from any parts store.
Be aware that the cover is thin, so don't strip the bolt holes.
This custom piece has worked for me for over 5000 miles now with no problems. If you don't weld aluminum and don't want to pay someone to do it for you, then this is an alternative.
BUT WAIT!!!!!!!!!!!!
Ha! Did you think you'd be done with it once you get the filler taken care of? NOPE :-)
You still need a bracket for the downpipe -- 16V c900 bracket isn't compatible with the 4-speed. Either track down a proper bracket (good luck) or fab something up. Couple things on this:
Saab used to attach downpipe brackets on 99s by "borrowing" bolts from the diff cover. They found, though, that the bolts would vibrate out, the tranny oil would liberate itself from the confines of the gearbox, and the car owner would get a new transmission from Saab.
Soooo, the other method was to borrow the inner driver bolts instead. If for some reason you choose to go the diff cover route, use some red loctite on the bolts. There really isn't a problem as long as you ensure the bolts don't vibrate loose. In fact, use red loctite on the bolts if you go the inner driver route, too.
As for using a c900 bracket -- I worked on "massaging" one to fit. Problem is, it's upside down as compared to the 4-speed bracket. If memory serves, I concluded that you can actually use it, but you'd have to remove the bracket if you ever needed to remove the downpipe!! NOT...
PS Yes, 4-speeds came in some early 900s...
posted by 128.208.20...
, Thu, 10 Feb 2005 14:45:52, Thu, 10 Feb 2005 10:44:02
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