Handbrake Button - Sticking
89saab07FILE IN VOL.
S.I. Man. I
SEC. PG.
A-5 33
Issue: 10/89-1180
Subject: Sticking Handbrake Button
Application: 1988-89 Saab 900 Models
The handbrake release button on some 1988 and later 900's may occasionally stick inside the lever assembly. This is caused by the actuator rod binding against the stamped dimple in the handbrake lever when the lever is forced downward past the full release position.
In order to prevent the button from sticking, a new handbrake lever assembly was recently introduced into production, starting at VINs K7034231 and L7000082. The new lever, P/N 41 03 206, has a modified profile of the ratchet sector which stops the pawl from over rotating.
Instead of replacing the handbrake lever to correct a complaint of a sticking button, it is possible to perform a simple modification to the lever which will limit the travel of the release mechanism. This modification can be done in the car without removing the lever, making readjustment of the handbrake cables unnecessary.
Figure 1:
Parts Required:
Roll Pin 81 17 640
Repair Procedure
1. Disconnect the electrical connector for the seat heater under the driver's seat and then remove the seat.
2. Remove the center console covering the gear selector assembly.
3. Remove the black rubber sheath from the handbrake lever by stretching it rearward to disengage the plastic rivets. Slide the sheath forward and off the lever. Raise the lever to the "up" position and push out the center pin in the rivets using a long, thin screwdriver Remove the rivets from the lever.
4. Measure and scribe the lever as shown in Figure
1. Use a center punch to mark the drilling location.
5. Using a 5.0 mm (No. 8) bit, drill a hole through both sides of the lever at the mark. Make sure that the hole is drilled perpendicular to the lever. Clean any metal chips from the release mechanism.
6. Carefully install a 5.25 x 20.0 mm roll pin, P/N 81 17 640, into the drilled hole ensuring that the pin is centered and secure.
7. Refit the handbrake lever sheath and rivets.
8. Refit the center console assembly.
9. Refit the driver's seat and reconnect the wiring for the seat heater.
Warranty Information: For warranty repairs use failure coding 55122-23-0-01-05. Labor allowance is:
0.5 hour as straight time for non-passive belt cars (0.6 hour as straight time for passive belt cars).