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
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.