Re: get ready for some fun... - Saab 900 Bulletin Board - Saabnet.com
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Re: get ready for some fun...
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Posted by JohnK (more from JohnK) on Wed, 25 Feb 2004 07:30:16 Share Post by Email
In Reply to: Unfortunately (or not) this sounds possible..., JS, Wed, 25 Feb 2004 05:40:45
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If you find melted wires and conjoined wires when you get under the carpet, you will need to unpeel the harness all the way up to the #152 bulkhead connectors. I had to remove the instrument cluster and the dash panel insert to get to the entire length of the harness and be able to unplug the 152 connectors. Also the fuse box needs to be lifted out.

The 152 connector can get distorted from the heat. The culprit wire is the heavy yellow(redstripe??) that goes from the ignition switch up to the solenoid. This sucker carries enough current to fry the starter solenoid braid and the damn thing is not fused. The worst engineering on an otherwise pretty well thought out car. I still get mad thinking about it! Believe me, you will forever keep the ignition switch clean and lubed.

However, with any luck, you will only have a few sections of wiring that need to be replaced. I would not try to replace the harness, just the bad wires. I did completely replace and reroute the yellow starter wire directly through the bulkhead to the solenoid, because the 152 connector was distorted at this wire's junction. I was able to reuse the 152 connectors, because the rest of the contacts were OK.

This job took the better part of a Saturday and a Sunday, and was the most tedious Saab project I have ever done. When finished, the sense of accomplishment was enormous and at least you don't get dirty. I strutted around the idling car for 5 minutes, I was so proud of myself. :-)) yeah I know, what a jerk!

posted by 208.208.152...

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