Author Topic: Graphite Green 9-5 Aero rescue  (Read 3774 times)

David

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Re: Graphite Green 9-5 Aero rescue
« Reply #75 on: 14 November 2019, 12:17:11 PM »
Most impressive results.  8)

carrera

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Re: Graphite Green 9-5 Aero rescue
« Reply #76 on: 14 November 2019, 05:14:14 PM »
Most impressive results.  8)

Thanks  :thumbsup:

Nearly there, took it for MOT today, a couple of really minor things that I'm annoyed with myself for missing and one void bush that I'll need to look into tomorrow.

I rediscovered the problem with the microswitch in the boot lock which means the boot lights stay on permanently. I think another mechanism will be needed.

The mirror triangles look good and I deployed the NOS Saab carpets yesterday (well GM, not quite the same as 2002 Saab quality)

Did you see the garage name on the number plates. Western Saab.......... I thought that was maybe your place, but I think they are in Glasgow, rather than Bristol ??
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David

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Re: Graphite Green 9-5 Aero rescue
« Reply #77 on: 15 November 2019, 09:31:02 AM »
As they say it is all in the detail !

No, tis not I, though I do live in Bristol. Western Saab is most definitely Glasgow , unless of course you put a 'Great' in front of it   ;D

carrera

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Re: Graphite Green 9-5 Aero rescue
« Reply #78 on: 16 November 2019, 03:56:54 PM »
Two contrasting pieces of work going on today:

Mirror covers have been fitted, to go with the painted triangles. I'm happy enough with them



and then the one significant issue from the MOT, upper rear transverse arm bush.

This photo shows what it is like with the rubber stripped off, and my home made tool to attempt to extract the old bush (and then insert the new one). Wish me luck.

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carrera

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Re: Graphite Green 9-5 Aero rescue
« Reply #79 on: 16 November 2019, 07:29:07 PM »
Hmm, 15+ years of rust makes this a tough job doesn't it.

I snapped the M12 bar twice, but on the third attempt I was able to destroy the rose joint and press that out, but leaving behind the outer section. At least that's what I think have done. I opted for a 41mm socket in the end.

The ring on the back tapped out with a punch quite easily, which left the hard steel outer part of the rose joint. I thought they were suppose to come out in one piece  ::)

I'm pretty sure that I just need to cut through this and then the remains of the rose joint will be able to be tapped out once the tension is relieved, but before I go completely crazy with the air saw I thought I would check seeing as I don't have the replacement part yet so cannot check the diameter.

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sgould

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Re: Graphite Green 9-5 Aero rescue
« Reply #80 on: 17 November 2019, 10:30:08 AM »
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carrera

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Re: Graphite Green 9-5 Aero rescue
« Reply #81 on: 17 November 2019, 11:40:12 AM »
Thanks for that, but those instructions are for the front part of the trailing arm. The job I am on with is one of the 4 transverse arm / radius arm bushes, item 12 on the relevant EPC diagram, at the outside end of what I would call the cross pieces

I have done the trailing arm bushes before, the Powerflex option is indeed the best route

The construction of the bushes is different, I'm thinking that the steel part of the rose joint is surrounded by an light steel / alloy outer, but before making the final cut want the reassurance that these bits need to be cut out. As usual I think the rust makes a component look more integral that it actually is.  ;D
« Last Edit: 17 November 2019, 11:49:26 AM by carrera »
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carrera

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Re: Graphite Green 9-5 Aero rescue
« Reply #82 on: 18 November 2019, 11:17:22 AM »
The replacement part arrived this morning so I was able to measure the diameter, which confirmed I should continue cutting.  I measured it at 45.35mm with a vernier caliper.

Heving felt the absence of movement in the new component, the minor play detectable from the MOT was actually a bush with perhaps very little play in the rose joint, but virtually no resistance to twisting movement, I could move it full range with my fingers..

I did two grooves, and then used a chisel to bend the small piece. Once it started to move the tension was broken and the remains were ready to be tapped out.

Next job will be to clean the interior surface up, lubricate it for insertion, and then pull the new bush in using my home made puller. Assuming that goes well, then when I have done the other minor jobs she'll be ready for a retest

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Sheltoncer

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Re: Graphite Green 9-5 Aero rescue
« Reply #83 on: 18 November 2019, 09:40:43 PM »
Does your homemade puller look like a regular puller, Carrera?

carrera

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Re: Graphite Green 9-5 Aero rescue
« Reply #84 on: 19 November 2019, 06:22:19 PM »
The rescue isn't finished yet, I have located a front splitter which will need a repair and paint, and the rear spoiler is also in for paint, but a significant milestone was achieved today.

12 months MOT, No Advisories,  :Fawlty: :Fawlty: :Fawlty:
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sgould

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Re: Graphite Green 9-5 Aero rescue
« Reply #85 on: 20 November 2019, 10:42:58 AM »
An MOT!  Well done. :)

My 2007 estate got an MOT without advisories on Friday. 168,000 miles. Must be time for some TLC if the weather warms up a bit. 
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Kev_Mc

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Re: Graphite Green 9-5 Aero rescue
« Reply #86 on: 21 November 2019, 09:40:25 AM »
Good result :)  :thumbsup:

Saved another 9-5. See fewer and fewer about these days..

carrera

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Re: Graphite Green 9-5 Aero rescue
« Reply #87 on: 21 November 2019, 01:06:21 PM »
Good result :)  :thumbsup:

Saved another 9-5. See fewer and fewer about these days..

That's 4 this year:

2004 2.0 saloon
2003 2.0 Vector estate auto
2003 2.3 Aero estate
2005 2.2 Tid estate

This car is going to become my daily driver, and as we like the glacier blue saloon that's a spare. The auto was going to be for my dad, but the insurance cost is silly so he's sticking with his 9000 Aero, so I should move the auto on. You may have noticed mention of a diesel. It's the first time I have ever worked on one of those. I didn't do a thread on that because the the initial glow plug extraction / repair was obvious though technical, and the subsequent non starting  is a common 2.2 problem, complicated in my case by some below par leak pipe remediation work done, which resulted in a missing copper washer seal at the pump. That one's up for sale at the moment.

That leaves me with the 9000 Aero to fix, the DE Aero that I am on with and then bodywork on my current daily, a 329k Aero
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carrera

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Re: Graphite Green 9-5 Aero rescue
« Reply #88 on: 04 December 2019, 06:23:30 PM »
A little more progress this evening.

With huge thanks to sgould providing an aerial I now have a working satnav   :thumbsup: :thumbsup: :thumbsup:

Another little job ticked off. The rear spoiler is about to be refitted having been lost in the bodyshop.

There's more good news though. JTC had a damaged spoiler which was almost broken in two places. After sourcing some plastic rods of the appropriate material I added plastic welding to my skills last weekend. It will need a bit of filler and finishing off, but with a bit of luck I might have a painted spoiler to fit this weekend. It will look like an Aero then.  :)

I'm not sure about the radio though. Touchscreen is definitely more distracting than the original push button. A twiddly knob is easier than the rocker switch too, maybe because it is bigger. It keeps losing it's memory too, but that's probably down to the battery that came with the car which finally gave up the ghost and died. I put another one on yesterday, let's see how that fares and how I adapt. 17 years with the same radio may take some retraining
« Last Edit: 04 December 2019, 09:28:37 PM by carrera »
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sgould

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Re: Graphite Green 9-5 Aero rescue
« Reply #89 on: 04 December 2019, 08:30:38 PM »
Glad it all worked! :)
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