I installed the Saab trailer hitch kit 48-25-667 on to 
our 9-5 wagon yesterday. Dealer quoted me 
US$500 labor to install. (!)

[I've also installed the mudflaps, side cargo net,
nylon retractable cargo net (goes up from back
seat), sliding load floor, and hands free cellphone
kit. Email if you need details.]

[Next on my list is the 12v cargo outlet, which
I dread as the wires have to run to the center 
console; good planning or what??!?!?!]

Took me about 6 hrs, though if you don't make bone 
headed errors like me, you could probably do it in 5.

So, for archival purposes, I will commit the following
addendum to the global cosmic consciousness.

Notes (correspond to step numbers in instructions):

****: get a blanket or quilt to use to rest the bumper
on the ground if needed during install. ****

3: you'll need a universal joint for 3/8' drive or a flex
extension to undo the 17mm nuts on the bumper.
One Torx (T-25) in wheelarch and one 10mm bolt 
underside. If you have mudflaps fitted you only
need to remove the three outer T-25's to remove
the bumper.

4: once unscrewed (T-35), the rear lights pull out 
to the side, not the rear.

6: the piece they are referring to is the upper black 
piece which is sort of a scuff protector. I removed
these 4 10mm bolts and forget them upon reinstall!!
(I was able to do it from under the car but leave them
in the bumper reinforcement)

8: the spacers are aluminum, held on with double sided
tape. Scrape the tape off.

10: very hard to get 20lbf ft without a motorcycle torque
wrench!! As these are self tapping screws, it is also easy
to strip the aluminum reinforcement as I found out.
Fix: 8mm (1.25 pitch) nuts and internal star washers
(I used 5/16' I think). You'll need to remove the 
reinforcement and notch the bumper foam to clear the nuts.
Probably stronger with the nuts there anyway. :)

12: no sealant to scrape off. Do NOT use the nuts
to hold the bumper on - too much work. Get a friend to 
hold the bumper hard against the car while you drill.

13: drill from the INSIDE of the car, using the sleeves
as guides. ($no39sdcx6spamx782#! Swedish translation). I used a 
wrench to push the harness down (both sides) 
while drilling. I used a 25/64' bit. It worked.

17: Terotex HV400 costs $35 for a tube from Saab.
I just used Rustoleam paint to paint around where I
had drilled.There was plenty of rustproofing already 
there as well. Dealer said they don't do anything 
special and don't use the Terotex either.

19: getting the 4 nuts done up is quite difficult. :/
I used Silly Putty to hold the nuts in a deep 17mm
socket and some string to lift the socket and
align it.

21: the inner ones may not line up correctly until the 
bumper is on tight. You may need to lever it a bit
to get the bolts lined up and started.

22 and 24: I think you could skip this.

28: screw was missing from kit. I used a self tapping
sheet metal screw. However I feel incredible guilt
that it wasn't a Torx screw. :) I also taped the 
ground wire out of the way of the jack storage.

Nicer finish than the 900/9-3 kit as no bumper
notching is required.

Glenn

• 9-5 wagon trailer hitch install, Glenn Wallace, Tue, 4 Jul 2000 10:57:32

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