SAAB WIS ONLINE

(731-2726) Front spring failure

MODIFICATION INSTRUCTION
Bulletin Nbr: 731-2726
Date: ........... January 2010
Market: US/CA
Front spring failure

Special Coverage 15917

This special coverage covers the condition described below for a period of 10 years or 120,000 miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. The repairs will be made at no charge to the customer.

Cars are to be rectified only after customer complaint.

Cars affected

Saab 9-3 (9440) M03-06 4d, 5d and CV located in Canada, Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Washington D.C., Vermont, West Virginia, and Wisconsin.

Background

On certain 2003-2006 model year Saab 9-3 vehicles, particles of gravel or stones may collect between the coil spring and the lower spring seat causing the spring to corrode. This corrosion may weaken the spring and in some cases, may cause the spring to break when subjected to high stresses at the corroded area.

Parts required

12 794 486 Zinc plate, 2 per car

Front spring, 2 per car (see EPC for the part number)

Procedure

This procedure pertains to both sides.

Checking method




1. Raise the car.

2. Is the front spring fractured?


See picture for the location of the fracture area.

Both sides must be checked.

No:

This car is not concerned by special coverage 159 17.

Lower the car.

Yes: This car is concerned by special coverage 159 17.

Go to the procedure for replacement of the springs.


Replacement of springs




1. Remove the MacPherson strut according to Tis2Web - Saab 9-3 - Suspension, wheels - Front suspension - Repair instruction - MacPherson strut.

2. Place the MacPherson strut in a vice.

IMPORTANT: Do not overtighten

3. Compress the spring with a 88 18 791 Spring compressor (A).


4. Remove the protective cover from the top side of the MacPherson strut. Hold the piston rod and remove the nut with 89 96 613 Sleeve, MacPherson strut (A).


5. Remove the support bearing (A), thrust bearing (B), water shield (C) (certain cars), dust excluder (D), spring (E), bump stop (F) and protective hose (G).


6. Compress the new spring with a 88 18 791 Spring compressor.

7. Clean the lower spring seat. Fit the zinc plate (H), bump stop (F), spring (E), dust excluder (D), water shield (C) (certain cars), thrust bearing (B) and support bearing (A).

Make sure that the lower end of the spring abuts against the stop in the lower spring seat.

Note

Protective hose must not be fitted.



8. Fit the nut.

Tightening torque 105 Nm (77 lbf ft)


9. Fit the protective cover.

10. Release the spring compressor.

11. Fit the MacPherson strut according to Tis2Web - Saab 9-3 - Suspension, wheels - Front suspension - Repair instruction - MacPherson strut.


Warranty/time Information

Replace front springs and add zinc plate Inspection of front springs only
Object code 15917 Object code 15917
Reason code 32 Reason code 40
Location code 01 Location code 01
Remedy code 01 Remedy code 08
Warranty type 32 Warranty type 32
Labor operation 1591701 Labour operation 1591702
Labor time 1.5 h Labor time 0.2 h


Customer Notification Proposal

Dear Saab owner,

As the owner of a 2003-2006 model year Saab 9-3, your satisfaction with our product is very important to us.

It has been established that the front springs for 2003-2006 model year Saab 9-3 may have a durability issue in regards to corrosion, most noticeable in areas where rust is most common, such as areas where salt is used to control snow and ice. Particles of gravel or stones may be caught between the spring and the lower spring seat. High forces will destroy the paint layer starting corrosion pitting on the raw metal that will accelerate in a corrosive environment. This corrosion may weaken a spring and in some cases may cause the component to break under high stress at the exposed location. When the spring initially fractures, the ride height of the vehicle lowers 0.4 - 2 inches (10-50 mm). This is accompanied with changes to vehicle steering and handling characteristics and most likely cause front end suspension noises.

Take your vehicle to your Saab dealer if you believe that your vehicle may have a fractured spring.

What We Have Done: Saab Automobile AB is providing you with this special coverage for replacement of a fractured front springs. If this condition occurs on your 2003-2006 model year Saab 9-3 within 10 years of the date that your vehicle was originally placed in service or 120,000 miles (193,000 km), whichever occurs first, your vehicle will be repaired for you at no charge.

What You Should Do: If you believe that your vehicle may have a fractured spring, take your vehicle to your Saab dealer and they will inspect, and if necessary, replace the front springs for you at no charge.

If you have any questions or need any assistance, just contact your dealer or the Saab Customer Assistance Center between the hours of 8:00 AM and 8:00 PM, EST, Monday through Friday. They can be reached at 1-800-955-9007.

Saab Automobile AB appreciates your cooperation and understanding regarding this action and we will do our best, along with your dealer, to minimize the inconvenience. We have, however, taken this action in the interest of your continued satisfaction with our products