1999 Saab 9-5 Problems

What owners report

Complaints on this model year center overwhelmingly on sudden stalling and no-starts traced to the ignition cassette/module, with owners often noting the part was replaced more than once and that a later recall for newer 9-5s did not cover this year. A second cluster covers cracked plastic fuel tanks and fuel vapor smells, and a smaller set describes brake booster, climate-control, wheel-hub and airbag complaints.

1. 1
   Electrical system

   Ignition cassette failure causing stall or no-start

   • 68 complaints (58%)
   • median 72,050 mi at 6.6 yrs old (62 state mileage)
   • 2 mention a crash, fire or injury
   • owner-quoted repair $550 (median of 13 quotes)
   • filed 1999–2011

   Owners describe the engine quitting without warning at speed, at stops or while accelerating, sometimes with a burning plastic smell or smoke from the ignition cassette (also called the DI/IDM module); others report rough running, misfires and a car that cranks but will not start. Complaints say the cassette was replaced, in some cases more than once, and that a recall covering later 9-5 model years did not apply to this year. Several owners report the dealer could not diagnose the problem until the part failed outright. Reported from under 1,000 miles to about 150,000 miles, most commonly between roughly 50,000 and 110,000 miles, with no clear seasonal pattern.

   1 related service bulletin

   What to check: Ask whether the ignition cassette has been replaced and how recently, and whether the car has ever stalled or failed to restart. A scan-tool check for stored misfire codes and a close look at the cassette for cracks or heat damage are worth doing.

   2 excerpts from owner complaints in NHTSA records

   “My 1999 Saab 9.5 wagon just died. It was towed to dealer. Dealer diagnosed and said ignition cassette was burned out. Dealer replaced the ignition cassette and spark plugs for $525.40 + 6.0% tax for total of $556.92. My mechanic said there was a recall on these cassettes. Dealer said my car was not covered. I paid the bill.”

   NHTSA complaint #10173064, filed 2006-11, 73,897 miles

   “Direct ignition cassette burned causing engine to stall. I was luckily able to drive in limp-home mode. Car taken to dealership. Diagnosed as burned dic. Mechanic stated that car should have died. Very fortunate to limp home. Dic replaced with new unit at my cost (out of warranty).”

   NHTSA complaint #10142230, filed 2005-11, 71,000 miles
2. 2
   Fuel system

   Cracked plastic fuel tank and fuel smell

   • 6 complaints (5%)
   • median 95,480 mi at 7.5 yrs old (5 state mileage, few)
   • filed 2006–2008

   Owners report the check engine light coming on with an evaporative-emissions code, fuel vapors inside the cabin, and inspection finding a crack or hole in the top of the plastic tank. Complaints describe tanks being replaced, sometimes more than once, since the plastic tank cannot be repaired, and note that the car cannot pass emissions testing with the leak present. In one case the tank was said not to hold pressure before being replaced. Mostly reported between about 74,000 and 150,000 miles.

   What to check: Ask whether the fuel tank has ever been replaced and check for fuel odor around the car and in the cabin. A smoke test of the evaporative system can reveal a tank or line leak before purchase.

   2 excerpts from owner complaints in NHTSA records

   “Leaking fuel tanks. I have replaced the fuel tank on this vehicle twice. The tank is now leaking again. The leaks cause the check engine light to come on (small evaporate leak code) and occasionally cause fuel vapors in the cabin. The tank is made of plastic, making it impossible to repair - must be replaced. Without replacement, vehicle will fail emissions testing and I fear fire hazard.”

   NHTSA complaint #10158850, filed 2006-06, 150,000 miles

   “The check engine came on recently and I took my 1999 Saab 9-5 to the dealer. After several attempts to correct the problem , it was found to be a crack in the fuel tank. The car was stored outside with little gas in the tank while waiting for Saab to locate a new tank. It has taken over 5 weeks and Saab claims no responsibility for the problem. My question is: have there been other reports of cracked fuel tanks made for Saab cars from 1999 to 2005 which all use the same tank?”

   NHTSA complaint #10158875, filed 2006-06, 95,480 miles
3. 3
   Brakes

   Brake booster leak and lazy brake response

   • 5 complaints (4%)
   • median 111,500 mi at 7.0 yrs old (4 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2004–2011

   Complaints describe the vacuum brake booster developing an internal leak or filling with oil, so the first push on the pedal in a hard stop gives little or no braking assist while normal braking still feels fine. Some owners also report the ABS module acting up, and one complaint ties a brake problem to a cruise control that would not disengage. Reported from about 71,000 to 195,000 miles, so mostly on well-used cars.

   What to check: On a test drive, make one firm, quick stop from moderate speed and feel for a hard pedal or delayed assist, and ask whether the booster, master cylinder or ABS module has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “1999 Saab 9-5 has a faulty master cylinder, and vacuum booster which both had to be replaced at owners expense. In the past the consumer had to replace the water pump. Heater fan motor, thermostat. Leaky sunroof, battery, battery cables and numerous light bulbs.”

   NHTSA complaint #10148678, filed 2006-01, 108,000 miles

   “Vacuum brake booster developed an internal leak, causing momentary loss of braking action when first stepping on brake pedal during an emergency stop. During normal braking the brakes worked fine. Important!...the big danger here is that you don't know there is a problem with the booster till you have to make a quick stop where you need to jam on the brakes quickly!! You suddenly fine there is virtually no brakes for a second or two!! In normal braking they work fine.”

   NHTSA complaint #10052759, filed 2004-01, 71,000 miles

Buying note. The ignition cassette is the item to sort out first: confirm whether it has been replaced and how the car behaves on a long drive, since a failure leaves the car without power. Also check the fuel tank for leaks and the climate-control vents for full function, as both are costly to put right on this model year.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.