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1980 900T Wastegate Rebuild
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Posted by Saabterranean [Email] (#2700) [Profile/Gallery] (more from Saabterranean) on Sun, 10 Aug 2025 12:49:01 Share Post by Email
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So I got a wastegate rebuild kit, including the poppet valve, diaphram, and the various gaskets that are part of the assembly. The disassembly and reassembly went fine, but I ran into trouble when I got to the final step. When I tried to connect the metal hose from the exhaust manifold to the top of the wastegate, the hose wouldn't reach. My first suspicion was that I had reassembled the wastegate incorrectly, but I double checked and didn't find anything obviously wrong. Admittedly, I found the description in the manual less than clear, but the visual seemed to line up with how I put things back together.

My second thought was that maybe the diaphram and/or gaskets were just a bit thicker than the originals, and the combined thickness was what was preventing the hose from reaching. I tried to straighten the hose to see if I could get it to reach, but no luck. I've also looked into having a slightly longer hose fabricated, but I haven't found anyone that can manufacture the flanges needed to fit the connections. I've also looked for some type of connector to extend the hose (e.g., for gas lines), but no luck so far due to thread differences. My last resort is to cut the hose and use a connection to lengthen it enough to reach, but I haven't found a place that can do even that.

Anyone with similar experience with a wastegate rebuild? Should I redo the entire job to see if I get a different result? Anyone know of a metal hose fabrication place that might be able to either make me a longer hose or extend the one I've got? I'm getting desperate as my SAAB has been inoperable for coming up on a year!

You can see the gap between the hose and the wastegate in the photo. Thanks in advance for any advice!

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