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09.08.2007: Rotors
A new 308 mm Aero rotor next to an old 284 mm version. A whole extra inch of size offers more leverage for stopping power.

Front brake upgrade on a 1995 Saab 900. The guide also applies to all NG900 (1994-1998), 9-3 (1999-2002) and 9-5 Linear and Arc models with 288 mm front rotors (1999+). See the regular brake service guide for general suggestions and bed-in procedures.

The upgrade is achieved by installing 308 mm rotors and matching calipers. The rotors are readily available from many retailers, and the calipers can be found on junk yards or purchased new from Saab. Suitable models to source the calipers from include 1999-2002 9-3 Viggen and 2000-2001 9-5 Aero. If you're upgrading a 2002+ 9-5 Linear, you need the calipers from a 2002+ Aero or Arc.

Early 900s (1994-1996) will also benefit from a larger pad size, as the original pads on these cars were smaller. Newer cars have the same calipers and pads as the Aero, but will require wider support brackets to accommodate larger rotors. Finding the brackets separately, however, might prove more difficult than complete calipers.

Another word of caution concerns the hub size on the early 900s (1994-1996 again). These cars came with slightly larger hubs, which do not fit into newer rotors. Measure your hubs and rotors before deciding on the upgrade. The old rotors had an inner diameter of 5½", while the newer ones are 5¼". If your hubs are too large, you can either cut 5 mm off the rim on a lathe or find a pair of hubs from a newer car. Oddly enough, my 1995 900 had small hubs that were a perfect fit for new style rotors.

Tools and supplies:

  • Torx E20 socket: caliper bolts (2002+ 9-5);
  • 18 mm socket: caliper bolts (1999-2001 9-5);
  • 17 mm socket: wheel bolts;
  • 11 mm socket: brake line banjo bolt;
  • 10 mm Allen socket: caliper bolts (NG900/9-3);
  • 7 mm Allen socket: caliper guide pins;
  • 5 mm Allen socket: rotor index screw;
  • Torx T25 socket: dust shield screws;
  • impact driver, drill and screw extractor (optional);
  • wire brush;
  • torque wrench;
  • anti-seize grease;
  • fresh brake fluid and bleeder;
  • car jack and stands.


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