1983, 1985 and 1990 Saab 900 Turbo Rebuild Projects
May 2005
Quite a bit has changed over the year. The full size Blazer was sold around christmas and
I bought a '90 900 Turbo that's in nice shape. Its main problems are oxidized paint
and a leaky heater valve. Replaced the heater valve and spent some weeks drying out the carpet
and padding on the driver's side. Also had the leather on the driver's seat resewn and a new
seat heater pad installed for $75. Next step: find a nicer stereo.
Sold the '83 a few weeks ago, and many of the parts from the '82 went with it. Have been
trying to sell the engine but no takers. Perhaps I'll give it away...
The '85 has been going strong (now 229K miles). Work performed since it arrived includes
a new headliner, new clutch system including hydraulics, SPG springs and UHMW plastic
spacers and new front shocks. I replaced the coolant system: water pump, belts, all hoses,
thermostat, etc. Of course nothing goes as planned, and I managed to break the drain
petcock while flushing the system. Fortunately the rad comes out easy and it was a cheap $15 repair.
So far it's a good rally car: Marvin and I nabbed 2nd in the Mountains to the Sea rally in
September after I rebuilt the front brake calipers. Found some studded Nokian Hakkapellita
tires and ran the Thunderbird Rally in British Columbia in
February. The car and tires did great, and we kept everything on the road. In early May I nabbed some
gravel tires and ran
the Heart of Darkness rally, also in B.C. and we did quite well. Details and pics on the
rally page. Next up is working the
No Alibi rally in June (Ellensburg, WA to Lewiston, ID and back) and then in
July I'll go down to N. California for the Golden West rally in the Yreka area. That
one I'll do with my dad. Should be interesting for his first event! The next major
purchase for the '85 will be some better seats. The stock cloth ones are quite
broken down and don't offer the lateral support I'd like so will look at some aftermarket
options.
August, 2004:
Plans have changed a bit. I still have the '83 as a daily driver and have picked
up an '85 900 Turbo 16v for an even better price. It will be a bit more initial work,
but the body and paint are in much better condition. The engine is strong and the
five speed transmission shifts smoothly. The clutch wouldn't hold pressure, so
I changed out the slave cylinder, clutch plate and other parts. Now it looks like the
clutch fluid line is the problem. So far I've fixed the doors and windows, cleaned up
the four inches of oil and antifreeze spilled in the rear compartment, and will hopefully
have the car mostly ready for a rally next month. Speedo and odo both work, and the odometer
shows 212K miles.
Drove the '83 over to Twisp, Washington, 200 miles away last week. Hot weather, torrential rain,
bruising hail and twisty mountain roads were no problem for the ugly grey Saab.
July, 2004:
Picked up an engine from a wrecked '82 Turbo last week. If I
would've acted faster, it could have been a better price (free)
but I managed to get to it before it went to the crusher. Nabbed
some other bits off it (A/C compressor, alternator, PS pump, and
more) as well for a very reasonable price. Here are some
pics:
Newer pics on the hoist:
Clutch-side,
back view
another view
June, 2004 Work so far:
- replaced front rotors, calipers and pads. Flushed brake
fluid. A few stories there, but hey, it's done. (Some bits were
VERY rusty, some tools were broken and some hot words were
spoken). Actually, rear brakes were worse than fronts, but those
look very easy to work on. Prolly just do the pads on those once
I find some replacement parts.
- hooked up the power steering. Getting a belt from the local
parts store was a joke -- they had many to choose from, just not
any the right size. Ended up getting a proper belt from
eEuroparts.com. Yes, it leaks, but it's nicer to drive. I keep a
bottle of power steering fluid in the front right fender well. I
will probably replace the rack someday soon. I check and top up
the PS fluid weekly.
- The drivers side window didn't have a bad motor. I tested
voltage to the motor and agreed with the seller's prediction of a bad motor and ordered
a replacement. But when it arrived and I tried to take the old
one out, the cause was clear -- the regulator assembly was
frozen/rusted shut in the up position. Let me tell ya -- getting
that sucker out when it's not "down" was an exercise I don't want
to repeat. Long story short: new motor, replaced the regulator
with a used one, greased and sealed both doors. Works now and I
will try and sell the old motor on saabcentral.com or ebay.
- Speedometer: Thought it might be the cable. Replacement cable
didn't fix. Tested cables ok, but they didn't turn with tranny in
motion. In-dash speedo seemed like it would work (stuck small
screwdriver in the back and tweaked it a bit to make the needle
move). Talked to guy at ScanWest on 2nd try and got sending gear
to replace in tranny. Removed old one and it was not there.
Prolly missing the four speed tranny was installed? Doesn't
matter. Speedo works now (verified with GPS that I started using
last week) but odometer doesn't work. Not as big a deal, but I
will likely replace the speedometer in the dash when I put a
new/rebuilt engine in.
- Stereo. Another long story short. Ten disc changer and head
installed. Four cheapo 4" speakers installed in stock locations.
Sounds like crap but it's pretty low priority at the moment.
Antenna was persuaded to work once I traced the proper connection
for the signal wire.
- small rust spots: I have taken some time to attack the
largest of the small rust areas on the car and sand/grind out the
rust and put in a temp fix with some vaguely matching gray paint.
Doesn't look too bad considering the rest of the paint on the top
sides of the car. I may not worry about the paint at all as I
love the idea of having a "sleeper" that looks like crap but can
churn some ponies once it gets going.
Other Things Of Note:
- The tranny works fine. In fact, when I described the car on
the saabcentral.com forum, one person said that folks would be
jealous with that engine/tranny combo. Seems just right to me,
though I really don't want to take the thing over 75 mph at this
time. Too much stress on stuff.
- After doing the Alcan rally last winter, I think I recognize
some of the paint damage on the hood and other leading edges of
the car. Talked to former owner and his dad had driven it on the
Alaska highway. It sure looks like the damage my friend's WRX
experienced after going up and back this winter.
- Tried to jump start a friend's Honda last week. Would not go.
Not enough amps or something, because he was able to get a jump
from someone else later. Strange. I notice that the lights are
definitely dimming/brightening with RPMs, so that will be
something to look at.
- Lots and lots and lots of oil comes out of the engine. So
much that I still haven't yet figured out what exactly is
leaking. Seems like stuff towards the rear of the engine. Now
that power steering is hooked up again, it's hard to figure out
what's PS fluid and what's oil. I have a lead on a "free" engine
that I will probably rebuild out of the car, taking my time and
many months.
- I love how some of the stuff still just works on the car.
Greased up the sunroof: works great. Hooked up the antenna: works
fine (though noisy). Took off the hatchback to R;@ampR rusty
hinges and reconnected some of the wires: central locking now
works all the way around the car. Hell, the clock works better
than the radio I put in!
- Car tends to die in the afternoons when I start it up to
drive home. Starts fine, but with a load it wants to stall. Only
lasts an minute at most. Not quite as bad first thing in the
morning.
- Still love to hear the turbo spool up. Still getting great
mileage compared to my old Blazer. Still lots of room for
improvement. Haven't had the knock that I experienced when I
brought it home that first day. I dig how it corners so flat,
though I'm still getting used to FWD on corners at speed. Need to
spend some more time with left foot braking on some loose roads.
Anyway, it's been my daily driver except when it's been on
jackstands waiting for brake parts.
Picked up a 1983 Saab 900 Turbo in April 2004. I've been
keeping something of a log of what work has been performed so
far. When I picked up the car, it had no power steering (missing
belt and reported VERY leaky by the seller). Among other reported
problems, the drivers side left window was stuck in the up
position. The paint is quite bad and the windshield looks like a
pack of kids with slingshots has been at it. Speedometer and odo
don't work. But it runs, shifts (with a four speed tranny from a
'77 90 model) and has decent tires.
July 14, 2004
Dan Comden
Seattle, WA U.S.A.
Email -- dan*@*comdens.com (remove the asterisks around the "@"
symbol)