Here is a list of the problems I had with my MY01 Aero estate which I had for 4 ½ years from new up to 91,000 miles. Overall I was very happy with the car, particularly the performance, comfort and build quality of the bodywork which still looks immaculate. The mechanics don’t seem quite as good, but Saab has handled the warranty well. Most of the problems are known and reported in other messages. Apologies in advance for the essay but sometimes you just have to get it down!
The SID failed early on (first year) and was replaced and has been fine since. Other early failures included the electric radiator fan fuse, which caused it to overheat in traffic, and a wiper motor that packed up. I’ve always wondered since whether the overheating caused any permanent engine damage.
I had problems with the gearbox from day 1 with moves into reverse baulking right from new. Second gear failed completely at about 30,000 miles and when fixed under warranty was found to be a cracked 2nd gear wheel. The gearbox gradually deteriorated and eventually proved impossible to get into reverse unless the engine was off and gear changes became increasingly notchy. This led to a major rebuild under warranty by the dealer, and was a ‘known problem’ with Saab having released a modification kit. I was annoyed that I’d had to be quite insistent with the dealer before this problem was looked at and then even more annoyed when they admitted that the kit was available and could be done under warranty. Even after the modification the car was still occasionally difficult to get into reverse and could jam when trying to move into lock position with the gearlever halfway, requiring the car to be rocked forward and backwards to move the gearbox enough to locate the lever properly. I presume this is the same problem with the synchromesh on reverse as discussed elsewhere on Saabscene.
The DI pack failed causing an engine shutdown whilst on one trip requiring an RAC pick up and drop at the dealer. It was then found that the exhaust cat was also damaged by the neat fuel that had been pumped down the exhaust so this had to be changed. Luckily this was all done under warranty. Some time later the DI pack failed again, this time outside the original warranty but covered by warranty on new parts so replaced FOC.
A new thermostat was needed outside warranty at just over 3 years and 54,000 and a new airflow mass sensor was needed at 62,000.
At the 78,000 mile routine service the dealer told me of a modification that Saab was recommending involving a new breather pipe and valve kit. I held off having the work done and when I called a few months later to book the car in for the work found that the modification had been withdrawn, it was causing more problems than it was solving! Instead of the modification Saab increased the engine warranty to 8 years providing the car had a full service history.
A problem with loss of power was traced to a throttle body seal at 86,000. Shortly after this the car began consuming oil and mayonnaise appeared on the oil dipstick and the 90,000 service confirmed a head gasket problem but Saab agreed to do necessary work under warranty. Further problems were highlighted with the rear suspension bushes and brakes, but these were only really to be expected in a car that is getting on for 100,000 miles.
Other work done included replacing drivers door window when the car was broken into on a visit to London and the repair of a dent in the bonnet and door which appeared after being parked on a public road. Dent Devils did the repair which was first class.
I’ve just replaced the Aero with a new 3.0 TiD so I hope this one proves to be a bit more reliable and I promise future posts will be shorter!
