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Similar problem, possible fix
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Posted by Ari [Email] (#2847) [Profile/Gallery] (more from Ari) on Thu, 25 Nov 2004 21:16:26 Share Post by Email
In Reply to: headlight problem, bob rosen, Thu, 25 Nov 2004 18:16:50
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I just did a fix this evening, so I can't guarantee that it's permanent. But-
A common problem with the Saab headlight relays is that they are mounted in the engine compartment. The heat and vibration take a toll on the solder joints. The relays are held onto the circuit board by the solder pads, so there is a lot of stress there.

I had the same problem - the headlights would drop out after a little bit, and sometimes over bumps. From the schematic, the headlight relay (the large, orange one) can cut out, but the headlights will still work on Daytime running light mode (anything but 'on') due to another circuit.

The solution is to pop open the relay and touch up the solder joints on the large pads holding the relays in place. When I inspected mine with a 10x magnifier, I saw cracks between the leads and the solder pads. The case of the relay is held on with tabs at the narrow ends - I use a thin screwdriver to pry them (carefully) apart - then the case just lifts off. Touch up only the large solder pads - the smaller ones don't have the mechanical stress, and you can overheat the delicate electronic components there.

The other solution is to buy a new headlight relay. Not cheap, but a good approach. I don't recommend a used relay, because this is a chronic problem. I've done this repair on a number of my 9000s, all the way back to my '88,.s

Good luck!

posted by 12.76.131...


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