|Originally posted by fast40driver:|
For clutch/flywheel, I just used stock parts. G6 dual mass flywheel, stock G6 clutch, G6 HTOB, G6 flywheel bolts - just bolted it together.
That will be the easiest approach. If you can find the complete passenger side axle assembly and install the Fiero outboard joint cup on it that will simplify things even further although it will require a shift of the assembly to the left (driver side) 1". The cobalt/Saturn Redline axles are weak due to a taper of the shaft going into the outboard joint and were strengthened for the switch from supercharged to turbocharged models in 08 which changed the outboard joint also making it no longer a direct fit for the Fiero hub.
Of course if you take this approach you'll need to have a custom shortened driver side axle which is still fairly straight forward and inexpensive through Moser racing which can make you a custom set of axles in the appropriate length, or a single axle, or shorten and respline a longer axle for even less ~$100.
Knowing what I know now from having performed this swap when it was still very new, I would send Moser a disassembled 06-07 Cobalt axle as a template (they'll need it to match the spline arrangement) and have them make me a pair of axle shafts in the appropriate length. If you score a G6 jack shaft which should bolt directly to the 3.4 DOHC block, you should be able to get away with only needing to swap the passenger side inboard joint assembly onto your new axle to avoid having to adapt the Saab jack shaft to the block. The reason is that the jackshaft for the G6 is male ended vs. female for the Saab and the joints different in size so the cups can't simply be swapped from one to the other.
If you do go with Moser, be forewarned, make sure they cut the joint retaining ring groove no deeper than what is found on the stock axle. I wasn't thinking when I saw that they cut the groove on my axle deep like that found on rear wheel drive axles and put the retaining ring on anyway only to realize after putting the joint on that it would be impossible to remove it because the retaining ring moved to an eccentric position and acted like a lock against joint removal.
[This message has been edited by Joseph Upson (edited 03-07-2015).]