Convertible Top Hinge - Deformation
SI.No. 811-2101PI No.
Date: October 1999
Distr.: all
9-3
Soft top cover latch jams due to deformed hinge
Cars affected
Saab 9-3 Convertible M98 - M99 up to and including
VIN X7063257.
Background
The soft top cover hinges flex when the soft top is in motion and when the soft top cover is opened and closed. This flexing occurs mostly when the soft top cover starts to open and causes the soft top cover to move forward, jamming the soft top cover latch pins in the latches. As a result, the breakpin (shear pin) in the soft top cover operating mechanism may break
To reduce the flexing, a new hinge has been introduced for fitting after customer complaint as described below.
Parts required
48 56 415 Hinge assembly left (CA: 30582848)
48 56 423 Hinge assembly right (CA: 30582849)
79 75 568 Bolt (x 4) (CA: 30509244)
51 16 967 Damper, soft top cover (x 2) (CA: 30582772)
62 35 178 Blind rivet (x 2) (CA: 30510074)
51 07 859 Wiring harness, soft top cover (CA: 30583079)
Procedure
1. Loosen and detach the luggage compartment trim. Protect the trunk (boot) lid.
Remove the covering over the 5th bow latch motor. Operate the soft top to its raised position (closed) with the fifth bow raised (standing straight up) and soft top cover open (straight up).
2. Measure the distance between the end of the hinge and the top of the flange on the nut. See figure.
3. Unplug the connectors for the microswitches and 5th bow latch motor. Cut the cable ties.
4. Remove the nuts and bolts securing the soft top cover to the hinges. Lift off the soft top cover.
5. Remove the soft top cover seal.
6. Detach the soft top storage bag from the rear edge of the bootwell.
7. Detach the outer end of the hinge spring with an Apex screwdriver without Torx bit or a suitable piece of pipe as a lever.
8. Remove the wiring harness from the left-hand hinge.
9. Tilt the rear seat backrest forward, and release the hydraulic pressure with the hydraulic system valve. Fold down the hinges and open the trunk (boot) lid.
10. Mark the position of the left-hand hinge on the body and remove the hinge.
11. Remove the bar with the springs.
12. Mark the position of the right-hand hinge on the body and remove the bolts securing the hinge.
13. Pull out the hinge from the joint.
14. Drill out the blind rivets securing the rubber damper pads and remove them.
15. Fit the new dampers.
16. Transfer the washers and clip nut from the old hinges to the new ones.
17. Press the right-hand hinge into the joint and adjust it to the marks. Bolt the hinge in place.
18. Put the bar with the springs in place.
19. Put the left-hand hinge in place according to the marks and bolt it into place.
20. Close the trunk (boot) lid and attach the springs with an Apex screwdriver without Torx bit or a suitable piece of pipe as a lever. Fit the new wiring harness.
21. Hang the soft top storage bag along the body edge and press the soft top cover seal into place.
22. Fit the soft top cover according to the distance measured earlier. Use the new bolts 79 75 568 on the impact member.
23. Plug in the connectors and fit new cable ties. Close the hydraulic system valve.
24. Operate the soft top for one cycle and check its fit and make sure the soft top cover and fifth bow lock correctly.
25. Carry out any necessary adjustments according to WIS.
26. Fit the covering over the 5th bow latch motor and vacuum the car to remove any cuttings.
27. Lower the soft top cover and open the trunk (boot) lid. Refit the luggage compartment trim.
26. Connect the diagnostic tool and clear any diagnostic trouble codes.
Warranty/Time Information
Failed Object: 81420
Fault/Reason code: 72
Location code (US): 3/4/5
Warranty Type (US): 01
Repair/Action code: 01
Labour Operation (US): 81420 (CA: B3595 - B3623)
Time: 1.1 hrs.
DISCLAIMER