(522-2351) Check/replacement of front brake calipers
Symptom: Reduced braking performance.
Longer than normal pedal travel to achieve desired braking effect.
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MODIFICATION INSTRUCTION
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Bulletin Nbr:
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522-2351
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Date:
...........
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maj 2002
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Market:
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enilgt sep. lista
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Check/replacement of front brake calipers
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Product safety campaign 150 09
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Cars in stock must be rectified before delivery.
A personal communication must be sent to the owners of cars already delivered requesting them to get in touch with the nearest Saab garage as soon as possible to have the fault rectified.
Saab 9-3 MY02 within VIN ranges 22038749-22042075 and 27013166-27014040.
The brake pistons in some brake calipers have receive the wrong surface treatment. As a result, when the brake caliper becomes hot, hydrogen gas can form, diminishing braking performance.
Symptom description
Reduced braking performance.
Longer than normal pedal travel to achieve desired braking effect.
As necessary
49 40 904 Bolt (x2 per brake caliper)
50 55 413 LH brake caliper
50 55 421 RH brake caliper
50 84 710 LH brake caliper, Viggen
50 84 702 RH brake caliper, Viggen
40-312 307 002 Brake fluid (sufficient for 25 vehicles)
16-30 06 442 White high-pressure grease paste (sufficient for 15 vehicles)
Before proceeding, inspect box A2 on the modification identity plate. If the box is not marked, proceed as follows.
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2.
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Check the number by the hose connection on the brake calipers.
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3.
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Is the brake calipers marked with the number 089?
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4.
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YES:
Brake calipers marked
089
must be changed. Continue with step 5 of this MI.
NO:
Mark the modification identity plate as described below.
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5.
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Remove the wheel on the side or sides on which the brake caliper requires changing.
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6.
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Press in the brake piston, using a pair of slip-joint pliers.
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7.
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Depress the brake pedal a short way with a brake pedal clamp and remove fuse 12.
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8.
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Remove the retaining spring from the brake caliper.
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9.
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Remove the brake hose from the brake caliper.
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10.
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Remove the two bolts securing the brake caliper and remove the brake caliper.
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11.
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Transfer the brake pads to the new brake caliper. Fit the retaining spring.
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12.
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Fit the brake caliper using new bolts.
Tightening torque 110 Nm (81 lbf ft)
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13.
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Fit the brake hose to the brake caliper.
Tightening torque 40 Nm (29 lbf ft)
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14.
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Remove the brake pedal clamp and fit fuse 12.
Bleed the brake system, as described under WIS - Brakes - Footbrake system - Adjustment/Replacement - Bleeding the brake system
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15.
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Fit the wheel, refer to WIS - Suspension, wheels - Wheels and tyres - Adjustment/Replacement - Wheels.
Tightening torque 110 Nm (81 lbf ft)
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16.
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Lower the car and depress the brake pedal to press out the brake pistons. Check, and if necessary top up, the brake fluid level.
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Marking the modification identity plate
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On completion of the necessary work, mark box A2 on the modification identity plate. If the work was carried out by the importer, mark the box with a "7". If carried out by the dealer, mark it with an "8".
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Time/Warranty information
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See separate information.
