SAAB 9-3 Convertible Top Lift Cylinder Rebuild & Made New Manual Roof Locking Bow With Tormach CNC

Repair the convertible top lift mechanism on a 2004 Saab 9-3. Removed and completely rebuilt one of the lift cylinders that was leaking. We also had to repair the manual locking mechanism that locks the front of the top onto the windshield since it was stripped. We used a Tormach 1100MX to make the new part after designing it in Fusion 360.
These Saab lift cylinders are not really designed to be rebuilt, the ends are crimped and we used a lathe to cut the crimped end off so we could take the cylinder apart. The pin that holds the cylinder in the car will keep the cylinder together so you don't need to crimp it back together when you are done.
Parts for these older Saab cars are hard to find. We could not buy the new locking bow and had to make one. The lift cylinders are also not available new. Since they are not designed to come apart, Saab does not sell the internal parts and seals but we found those at a local hydraulic shop, Hose-Fast in Garland, TX.
Saab Lift Cylinder PN - 12833509
Cylinder Base Oring 1.8x13.3mm
Piston Seal PN - MPS-16x2x1
Rod Seal PN - MKR-8x13x2
Tiny o-rings where the hose hooks on Cylinder - Saab PN 32019444 (5.3x3.3mm is what I measured)
Saab Convertible Roof Locking Bow PN - 122114100
Precision Matthews 1440TL lathe used to cut the end off the crimped cylinder.
Thanks for watching!

[@fearnoproject2047]

That top architecture, mechanism and sequence is pure art.

[@BladesIIB]

@fearnoproject2047- Yes, the SAAB engineering is pretty impressive.

[@1antonio516]

Great Video! I have a similar issue w/the top on my (well, now my Daughter’s) 2008 9-3 CV top. I also have a mechanical design background (using CREO 3D), and lite shop experience (academic and job). Very cool to analysis, draw up a plan, CAD it, create it, apply it, and enjoy the moment it works. SUCCESS!! Thank you for posting. I’ve subscribed. Looking forward to more.

[@BladesIIB]

Anthony Carswell - Appreciate the feedback on the video and the process. Thanks for the sub! Good luck with the repair on your daughters car.

[@davezgy1]

Thank you for this video! I’m currently in the process of rebuilding the 7th bow cylinder on a customer’s 2004 9-3 Aero convertible. The 2 o-rings at the top of the cylinder look to be hidden in there pretty good, hopefully I don’t run into too much trouble putting them back in.

[@BladesIIB]

davezgy1 - Glad the video was helpful. Those top small ones are a little tricky, just take your time. The o-rings go in pretty easy, the stuff nylon seals take a little work. I used the plastic tools to ensure I did not damage them and had a wooden dowel in from the bottom to push against to get them started in the groove and keep from pushing them past. Good luck! Thanks for the comment.

[@fearnoproject2047]

On my 05, it was the two rams lifting the decklid, that started leaking first. I heard the windshield lock ram is a real mess when it fails, so being proactive will prevent oil soaked canvas, headliner and carpet.

[@BladesIIB]

@fearnoproject2047 - Yes, shortly after we repaired one cylinder another one became the weak spot. I am thankful it was not the windshield lock ram though, I can’t even imagine the mess that must make. Thanks for the comment.

[@minskmade]

love you showing the whole fusion360 to mill process....awesome....great video

[@BladesIIB]

minksmade - Appreciate the comment and glad you enjoyed it. I try to show that full process in my other CNC videos as well. Has been a learning journey for me to learn CNC and trying to help others along the way.

[@minskmade]

@@BladesIIB i looove fusion 360..i have a diy built cnc router and a cnc plasma cutter i built...i am still learning...i just got into metal work over the covid season :). manual lathe manual mill etc..... thank for the awesome videos

[@BladesIIB]

@@minskmade My pleasure. Sounds like you have some serious tools to work with. Congrats!

[@Prymasek]

Great video, I got same issue and will be working on it this week. Thanks for the tips !

[@BladesIIB]

@Prymasek - Awesome, glad it was helpful. Good luck getting your back up and running.

[@tdg911]

Yes another functional successful part. Every household should have a welding machine, cnc mill and a lathe. Have all 3 here and when in doubt... model it and make it lol. Always good content Bud. Still waiting on that beta knife test :P

[@BladesIIB]

tdg911 - I agree, those should all be household items. Glad you have them 😁. Appreciate the comment, hope you are doing well. Just got some new springs after some feedback from the Blade Show in Atlanta so the knives are getting a new lock spring tune up.

[@bigfist255]

Yeah same thing happened to mine ,I got one off ebay to replace it and then purchased and recon 1st bow, they are the smallest and most expensive ones .

[@BladesIIB]

@bigfist255 - Cool. Glad you got your all fixed up. Thanks for the comment.

[@CratesViral]

Around 5:35 my lockingbow broke in the locked position can't get it open to change

[@BladesIIB]

@CratesViral - We were able to get enough pressure in the hydraulics to open ours. If you can't do that, I am not sure what other options you have. You could cut a larger hole in the trim to access, but not sure how you would fix that after unless you can find another ceiling trim piece. I don't have the car anymore so maybe another Saab expert can help you out? I do still have the part available if you do get yours out and need one. Good luck!

[@ollyit]

Superb video, and well documented, sorry if ive missed this detail do you have the size please of the 2 smallests o rings that sit in the ram body, where the 2 x hydraulic lines plug in please? many thanks in advance, Olly from the UK

[@BladesIIB]

@ollyit - Glad it was helpful and thanks for the question. Since we found the original Saab parts for that I did not include the size in the video. I do still happen to have one and my best measurement on it is 5.3x3.3mm. The Saab part number for a set of 4 with the clips is 32019444 and it looks like they are still available on Europarts.com right now. Hope that gives you what you need. All the best with your rebuild.

[@ollyit]

@@BladesIIB thank you for taking so much for taking the time to reply :) it helps keep these great cars on the road, I was successful at saving my rear passenger side tensioner (i think) ram but cutting end off and replace the o ring, thank you so much from the UK - all the best olly

[@BladesIIB]

@@ollyit Thanks for sharing. Glad you were able to get it repaired. 😀

[@makgou9148]

1/8" drill bit drilled straight down takes the dimple out the easiest.

[@BladesIIB]

Mak Gou - Thanks for the tip! Likely have to do the other side and that will be much cleaner for sure. Appreciate the comment.

[@terryschwartz5429]

How do you know of its leaking? Great video thanks.

[@BladesIIB]

Terry Schwartz - In our case it was leaking mostly when the roof was down. When down it leaked enough it left a pool of hydraulic oil on the floor by the back tire. The reservoir will get low in the trunk and operation of the roof will fail as it can’t build pressure. Lots of ways you will know you have an issue. Thanks for the question.

[@inrissk]

Nicely done! My 2006 convertible says only manual operation possible contact dealer. Is there a way to reset or override that? Thanks in advance!

[@BladesIIB]

Steve K - I am not familiar with that? For my sons car it just stops moving or gets an obstruction error when the pressure was to low. Filling the reservoir would usually get a few more ups and downs before it all leaked out. Never a hard stop error that did not correct itself. Thanks for the question, sorry I don’t have a better answer for you.

[@Explore-Gobal]

Don't suppose you would craft one of those locking cams for my car?

[@BladesIIB]

YesUCan - I am sure I can be persuaded. Feel free to send me a PM on Instagram same name BladesIIB (BladesiiB) or use the contact form on my website - www.BladesIIB.com

[@zakbrinkhoff324]

You should make up a couple of them and sell them please

[@richardholliday1087]

Any chance you would sell the CAD/CAM file for others to use to make the part locally?

[@billykeramidas3806]

Hello thank you for your video. I have w209 Mercedes benz that uses the same cylinder. It losts pressure and oil by the top O ring (between the tube and an aluminium peace with the two seals that holds the saft) . Can you tell me how can i replace it?

[@BladesIIB]

billy keramidas - Thank you for the question. If the cylinder is the same as this one you can follow my steps to rebuild your cylinder. For the Saab, the company is out of business so parts are hard to come by. For your Mercedes you can likely contact a dealer to see if a replacement part is available for you. Apologies, I don't have more information for you. This was a one off project to get my sons car working again since we could not buy to part from Saab. Good luck getting the parts you need for your W209.

[@shan3964]

Hello there Great video, I was wondering if you could make another locking bow for my Saab 08 convertible? I have the same problem the piece is stripped out ,if not do you know what the part number is?

[@BladesIIB]

@shan3964 - I do have two locking bows available right now, they are on the store page on my website www.BladesIIB.com. I am not a Saab expert so I am not sure if the part for the 2008 is the same or not. The part number this one is built after is part number 122114100, that was cast right in the original part. If you take a look a the one for sale on my site you can see the pic of the original and see if it is the same as yours. Get it ordered and I can send out next day. Cheers!

[@merrillmccoy2247]

Excellent instructions. Can you give quantities of each seal and o-ring. Thanks

[@BladesIIB]

Merrill McCoy - Glad the video was helpful. If you check out the video at 26:36 it walks through all the parts with part numbers. Basically you need one 0Ring for the end. One Piston Seal which is an ORing and a Wiper and 2 Rod Seals each with an ORing and a wiper. The piston and rod seals come as a set Oring and Wiper together. Good luck getting your rebuilt.

[@merrillmccoy2247]

Thank you so much.

[@BladesIIB]

@@merrillmccoy2247 Welcome!

[@fearnoproject2047]

Amazing work! Draining and cleaning out the pump reservoir a couple times with fresh oem recommended fluid will prolong the seals too. The stuff that came outta my 05 a few years ago was naaasty with lots of metallic glimmeries in it. Love these convertibles!

[@somethingoriginal5158]

Any info on how to get to the manual latch?I also need that replaced but it seems that one of my roof locks aren’t working and the roof is stuck closed. So I’m hoping removing the trim piece will help me furthermore

[@BladesIIB]

Something Original - Thanks for the question. The interior trim piece does come off that front top section of the roof to access the lock. When it is not stripped there is a hole through the trim that allows you to put the tool through to manually lock and unlock. You should only have to remove the trim to access if you are replacing that part. I don’t recall the exact clips holding that section of trim in place, my son pulled that apart but he seemed to figure it out without damaging it. Hope that helps, let me know if you need more and I will ask my son if he remembers. If you do need the part, let me know. I just sold one to someone else and happy to make more.

[@dannyconteres3821]

@@BladesIIB I am have the same issues are you able to help me out ? . The lock to the front part of the convertible is stripped , I need help removing the cloth to get access to the bolt itself and then replacing it .. exactly what you did in this video lol

[@BladesIIB]

@@dannyconteres3821 I will try and get more details about removing the trim. My son is going to try to video it today or tomorrow. Let me know if you need the part?

[@BladesIIB]

Something Original - I did a short video today showing how to remove the trim. Unfortunately, the top has to be open to access the screws. If you can find the trim at a junkyard you may have to cut yours to repair? Hope this helps. kzbin.info/www/bejne/epbbi5mMZrFlaKM

[@terryschwartz5429]

Where do you get that size orings?

[@BladesIIB]

Terry Schwartz - We went to a local hydraulic cylinder repair shop to order the o-rings and seals. I put the part numbers in the video as well to help you search and see if you can find them online. Good luck with your rebuild. Thanks for the question.

[@markglassen]

May I order a manual roof locking bow? Have a 2004 SAAB 9-3 AERO Conv. where I've stripped the female socket also.

[@BladesIIB]

Polestar - I can definitely make another one. Send me a PM on Instagram, same user name (bladesiib) or use the contact me form on my website www.BladesIIB.com. Thanks!

[@BladesIIB]

Polestar - Thanks for reaching out. I replied to your email and sent you a text.

[@jmsteed]

Did you replace the ring you lathed off or is it fine without it?

[@BladesIIB]

Jason Steed - Thanks for the question. The "ring" I machined off was the crimped portion of the original tube so no way to put this back on. The pin that goes through the hole actually holds the tail section in place so it is fine without it. When removing the crimped section remove just enough for the tail section to come out, if you remove to much you will get closer to the hole the pin goes in and that could weaken it. I am sure the manufacturer has some fancy way to remove the crimp, or maybe they just use a new tube if they rebuild? More than likely they were never designed to be rebuilt but thankfully it is possible. Good luck with yours, happy to answer any other questions if you have them.

[@jmsteed]

Thanks for the reply. I was able to rebuild mine and got it working!

[@BladesIIB]

@@jmsteed Awesome, glad you got your operational! Appreciate the comment.

[@dannyconteres3821]

Where are you located ? I have the same issues my Allen lock is stripped and I have no idea how to take off the cloth material to get to the bolt how you did .. can you work on the car lol contact me please

[@BladesIIB]

Danny Conteres - i am in the Dallas metroplex up near McKinney. I will see if my son can take a quick video of how to remove the trim piece to access. Otherwise he will be home with the car in a couple weeks and we can get a video. Let me know if you want the part and I will get one made. You can reach out to me through the contact link on my website www.BladesIIB.com.

[@dannyconteres3821]

@@BladesIIB okay sounds good thank you sir .

[@BladesIIB]

@@dannyconteres3821 Here is a link to a short video about removing the trim to access the part. To remove the top needs to be down or open so if stripped May need to fill and leak some fluid to get the top activated. SAAB 9-3 Convertible Remove Trim To Access Roof Locking Bow kzbin.info/www/bejne/epbbi5mMZrFlaKM

[@wags9777]

You must mean rotary tool every time you say dremel tool? Dremel is a brand .

[@BladesIIB]

Wags - That would be correct.

[@Explore-Gobal]

So glad you pointed that out, I was so confused as I had no idea what he meant? Is he a sponsor of Dremel Tool, did he mean using a rotary tool, did he mean that the Dremel tool is the only one that could do the job? Oh my goodness, so much confusion. Thank you, thank you, thank you.

[@shannonkai1540]

This doesn't cover all 9-3's. Misleading title.

[@BladesIIB]

@shannonkai1540 - I make no claims to be a SAAB expert, and I am not trying to mislead anyone. Based on your expertise, what would be a more appropriate title?