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2002 Saab 9-5 repairs by problem area

Engine (51%)

Transmission and Drivetrain (3%)

Brakes and Traction Control (3%)

Suspension and Steering (10%)

Electrical and Air Conditioning (24%)

Paint, Rust, Leaks, Rattles, and Trim (3%)

Other (6%)

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Chart based on 163 repairs.

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2002 Saab 9-5 electrical repair cost distribution

$2500+ (0%)

$1000 - $2499 (9%)

$500 - $999 (11%)

$100 - $499 (31%)

< $100 (49%)

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Chart based on 35 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

91000 mi

When sold needed AC work.

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US $1000	Alternator died, battery 1 month later
155000 mi US $320	Air distribution system faults
196000 mi US $68	ACC code 21, replaced recirculation motor with used unit
202000 mi US $35	Xenon bulb failure. Replaced both bulbs with aftermarket units.

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96000 mi US $674	Air conditioning stopped being cold. Dealer found broken drier accumulator. Replaced part, refilled refrigerant, now it works fine. Dealer provided a loaner vehicle while mine was in the shop.
106600 mi US $155	Driver's side temperature control lever for HVAC was cracked bc of a design flaw, causing the system to require frequent "calibration" to operate. If left unrepaired, more extensive damage is possible.
112700 mi US $15	Subwoofer foam cone edge deteriorated. I obtained a repair cone edge and glued it in place.
120000 mi	False alarm. Computer reprogrammed to disable alarm module.
124200 mi US $900	Motors that operate air control flaps failed.

94000 mi US $80	Had the SID display module in the dash rebuilt to address the common missing pixel problem.
107000 mi US $50	replaced both LH and RH HID headlight bulbs, removed LH headlight assembly to removed broken bulb glass and to free up the high beam shutter mechanism, replaced turn signal bulbs while I was in there
156300 mi US $40	Major repairs on under-dash HVAC unit. Replaced broken driver side blend door lever and disassembled and lubricated passenger side blend door system and air distribution system. Major pain in the neck and back (literally). Added 12 oz R134a.

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36000 mi	Dealer replaced psgr mirror tilt switch under warranty.
49900 mi	Dealer repaired broken seat belt buckle assembly under warranty.
68000 mi US $70	Replaced psgr side DLR (requires removal of entire headlamp assembly)
78000 mi US $70	Replace drivers side DLR (requires removal of entire headlamp assembly)
116000 mi US $350	Replaced theft siren assembly (alarm would go off unprovoked) (first replacement)
168500 mi US $225	Replaced both Xenon headlamp bulbs. Refurbished hazy plastic headlamp lens panels to clear finish. Replaced both Xenon headlamp bulbs. Refurbished hazy plastic headlamp lens panels to clear finish.
169000 mi US $225	Replaced both Xenon headlamp bulbs. Refurbished hazy plastic headlamp lens panels to clear finish.
178000 mi US $130	Freon Recharge for A/C System Freon Recharge for A/C System
202000 mi US $1190	Blower fan inoperable. Replaced HVAC control unit, and underdash flap motor and linkage arm.
216000 mi US $1030	In shop for rear pads & rotors. Also replaced alternator and serpentine belt tensioner (1st replacement for each).