Recall - ABS Pressure Switch Inspection: Overview
CATEGORYRecall
SECTION
9
PAGE
19
ISSUE
08/95-0611
CODE
521
Subject:
Recall 295
Inspection of ABS Pressure Switch
Application:
1992 9000 All
1993-94 9000 Turbo with Manual
Transmission and Traction Control Only
VIN Serial No. Ranges: N1000001 - N1049024
and P1000001 - P1042386; R1000001 - R1026535
Supersedes PSI 07/95-0596
Safety - related
1992 9000 All,
1993-1994 9000 Turbo Models with Manual
Transmission and Traction Control
NHTSA 95V - 067
The Campaign
Saab Cars USA, Inc. has notified the National Highway Traffic Safety Administration (NHTSA) that a defect which relates to motor vehicle safety may exist in certain 1992 and 1993-94 9000 models.
On certain 1992 9000s and 1993-94 9000 Turbos with manual transmission and traction control, it is possible that moisture (especially when using high pressure water to clean the engine compartment) can follow the Mk II ABS harness and enter the connector on the pressure switch. This can result in corrosion on one or more of the five pins on the switch. The resulting deterioration of the electrical contact in one or more of the contacts can result in false illumination of ABS and/or brake warning lights and/or the loss of power assistance because of no hydraulic pump operation.
All ABS connectors are to be removed and inspected for signs of damage and/or corrosion. If the switch is corroded (estimating 5% of the time), it is to be replaced. In all cases, blow dry the connection, spray "Kontakt 61" on the connection and fit a shrink hose to the wiring harness/pressure switch connection using the adhesive contained in the kit.
Vehicles Affected:
1992 9000 within the following VIN Serial No. Range:
N1000001 - N1049024 (All)
1993-94 9000 Turbo with manual transmission and traction control only within the following VIN Serial *No. Ranges (check DCS Recall Inquiry for actual VIN confirmation)*:
P1000001 - P1042386
*R1000001 - R1026535 (only 32 cars with optional TCS affected)*
Recall Schedule:
Dealer Notification (DCS E-Mail) April 5, 1995
Saab Press Release April 17, 1995
PSI Bulletin issued June 20, 1995
Owner Notification July 1 1995
Start of Repairs July 15, 1995
Parts:
Recall 295 Kit # 1
(Consists of shrink hose & adhesive) 46 68 737
Terminals 91 20 957
Recall 295 Kit # 2 89 94 071
(Consists of ABS pressure switch, shrink
hose & adhesive)
Kontakt 61 Connector cleaner 30 04 520
An initial parts order of Kit P/N 46 68 737 equal to 25% of the vehicles appearing on your Status List will be released automatically to you commencing the week of June 26, 1995. Each dealer will also be issued one Kit P/N 89 94 071, one can of Kontakt 61 and five terminals, P/N 91 20 957 for use in this repair. Additional quantities should be ordered using VOR ordering procedures.
Action:
Unplug the wiring harness connector (Figure 1, item 1) from the pressure switch (Figure 1, item 2) and *check whether the switch contact pins or the wiring harness cable terminals are severely corroded. If the switch terminal is severely corroded and cannot be cleaned, carry out Action 2, otherwise only Action 1.
Before attempting to replace any ABS pressure switch, try to first clean off any corrosion on the ABS pressure switch terminals This should be effective where there were no existing ABS problems or illumination of the ABS warning lamp Kontakt 61 will restore a good electrical connection even if a small amount of corrosion remains.*
Action 1
Spray with Kontakt 61 cleaner and seal the connector with kit P/N 46 68 737 as noted below.
*1. Peel back the connector's rubber shroud along the cable. See Figure 2.*
2. Mark the leads and withdraw them from the connector.
*3. Pull the rubber shroud off the cable. NOTE: If the rubber shroud shows signs of damage, discard it.
4. Inspect the cable terminals for moisture and corrosion. If the cable terminals display the effects of corrosion, they must be changed. Otherwise, blow them clean and spray them with Kontakt 61 cleaner.
5. If the cable has PVC sheathing, cut away 70 mm of it.
*6. First fit the shrink tubing over the cable, then fit the rubber shroud over the cable if it is undamaged. See Note in Step 3.
7. Install the leads back in the connector and if undamaged, pull the rubber shroud back over the connector.
8. Position the sleeve of adhesive about 20 mm from the rear edge of the rubber shroud or the connector housing and pull the shrink tubing forward so that it covers the edge of the shroud or housing. See Figure 2. Leave a space between the shrink tubing and PVC sheathing, if any, at the other end.*
!WARNING
The use of a cigarette lighter or any other kind of flame is prohibited.
*9. Carefully heat the shrink tubing with a heat gun until shrinking is completed and the adhesive has melted. Stan applying heat at the edge of the connector end so that the shrink tubing is correctly secured and seals over the edge of the shroud or connector housing.*
10. Spray with Kontakt 61 and plug the connector into the component.
Action 2
*1. Check whether the wiring harness cable terminals are severely corroded. If they are, change them using P/N 91 20 957.*
2. Seal the connector with shrink sleeve and adhesive as described in Action 1.
3. Change the pressure switch.
*IMPORTANT
Do not force a switch that will not unscrew under normal torque. Destruction of the threads in the ABS pump housing will require the replacement of the ABS assembly. Do not replace the switch. Scrape the corrosion oft as best you can. Spray with Kontakt 61. Kontakt 61 will restore a good electrical connection even if a small amount of corrosion remains.*
4. Spray with Kontakt 61 and plug the connector into the component.
Warranty Information:
When submitting a Recall 295 Campaign claim, the following information must be included on the claim:
Action 1: Clean with Kontakt 61 and if no corrosion on the terminal is detected, seal the contact housing.
Failure code: 10295-66-0-05-05.
Recall Action Code (RAC) = 3 must be used.
*Operation No.: 10295 for 0.6 hr.
Sublet allowance: $1.00 for Kontakt 61*
Action 2: If corrosion is detected, seal the contact housing, replace the wiring harness cable terminals and change the pressure warning switch. Clean with Kontakt 61.
Failure Code: 10295-66-0-05-01.
Recall Action Code (RAC) = 3 must be used.
*Operation No.: 10295 for 0.6 hr.
Straight time: 0.4 hr.
Sublet allowance: $1.00 for Kontakt 61
Please update your DCS Tables as follows:
Failed Part Code: 10295
Description: Inspection of ABS pressure switch, Recall 295
Operation Number: 10295
Trans. Type: B
Engine Type: 9
Models: 9000
Hours: 6 hours
Begin year: 92
End year: 94*
After the car has been modified, mark the campaign plate in position B3 using a numeral "8" (Saab Special Tool P/N 02 97 713). Order this special tool directly from Kent-Moore at 1-800-345-2233.