Saab 9-3 2002 Steering Issue

Investigated “clicking noise” on steering.

Vehicle is in very good condition.

The o/s steering rack mount. Severe corrosion and cracks. I have to take that bracket section off!
knoba - saab 9-3 2002 steering issue - 01

~§~

The yellow markings indicate places where the bracket was hanging on. The entire left side (cracked, top to bottom), lower end & 2 spot welds (by the stud fixing holes), of this (2.4mm plate) are supposed to be a structural part of the vehicle.
knoba - saab 9-3 2002 steering issue - 02

~§~

Lower end of the bulkhead mounting bracket has completely rusted away.
knoba - saab 9-3 2002 steering issue - 03

~§~

View of bulkhead corrosion (engine bay side) after bracket was removed. Bracket is source of corrosion initiator.
knoba - saab 9-3 2002 steering issue - 04

~§~

Chasing the rust caused by this bracket; inside o/s wheel arch…
knoba - saab 9-3 2002 steering issue - 05

~§~

Chasing the rust caused by this bracket; interior o/s floor well. The tyre can be seen through wheel arch (on right) & the main chassis rail (centre of hole)…
knoba - saab 9-3 2002 steering issue - 06

~§~

Why did it fail?

Closer inspection, of the bracket tear, reveals a saw tooth edge. Suggesting repeated side impacts on the wheels, possibly caused from parking up curbs and such…
knoba - saab 9-3 2002 steering issue - 07

~§~

Even with the flimsy fixings remaining on the bracket, it doesn’t account for the amount of movement available to create that tear. Further investigation resolves it; crack in bulkhead…
knoba - saab 9-3 2002 steering issue - 08

~§~

Cut out all rust. Make & weld in new sections (upper floor pan, lower bulkhead, wheel arch). Modify & re-attach bracket (extend lower section, weld to main chassis rail). Weld bulkhead crack from interior side. Dress, seam seal, prime, paint & underseal.

•••

Advertisements