Well I finally got around to doing this mod. There was a learning curve to go thru because there are small differences that had to be addressed. The front brakes on the G6/SS are 11.7 inches. The Saab 9-3 ( built on the same Epsilon platform as the G6 / Malibu ) has a brake size very similiar at 302mm. But the Saab 9-3 also has TWO LARGER BRAKE SIZES for the 9-3. They are 314mm (12.4in) and 345mm (13.6). The 345mm just came out on one model, the Saab Turbo X. I did the 314mm because the parts for the 345mm setup are MORE expensive and harder to get, plus I was not sure if they would bolt up since I had not seen them installed on a Saab. Let me start with what is needed parts wise:
1) Two Calipers
2) Two Caliper Brackets
3) Two Rotors
4) Set of pads
5) Two Banjo Bolts that fit the Saab Caliper (they bolt the brake line to the back of the caliper)
6) Four washers for those same banjo bolts (two for each side)
7) Four Grade 10.9 Metric Bolts (14mm diameter x 45mm long with a 2.0 thread pitch) these bolt the caliper bracket to
the back of the spindle
Two new front brake hoses for your G6
The calipers, brackets, rotors, pads, banjo bolts, and washers are all Saab parts available from a Saab dealer or from an auto parts store. The bolts need to be obtained from a good hardware supply location.
The first hurdle is that the bolts used by the G6 to bolt the caliper bracket (the caliper is first fitted into the caliper bracket and then the bracket gets bolted to the rear of the front spindle) to the spindle are smaller than the Saab ones. You need to get four of the bolts listed above which are larger and fit the Saab caliper bracket and will thread into it. You can just take the bracket with you to make it easier to find the bolts. It is VERY important that you get the exact ones and in the GRADE listed. The grade determines the strength of the bolt.
Next is you need to drill the two holes that are in the spindle a little larger so that those bolts will pass thru. It is only a slight increase in diameter. Not hard to do since the spindle is made of aluminum. Use a 9/16 drill bit. See the pics that I will get posted soon.
Another difference is the banjo bolts used to bolt the front rubber brake line to the back of the caliper. The Saab uses a larger banjo bolt. This is where getting the new front rubber brakes lines comes in. It will be easier to do this step BEFORE you start. Take the new brake hoses and drill the hole that is on the flat end a little larger so that the Saab banjo bolt can pass thru. This is probably the hardest part. You may want a machine shop to do this. It needs to be done cleanly, exactly centered, and the hole made only large enough to fit the new banjo bolt. The washers go on the banjo bolts. One goes on each side of the flat end of the hose (so you need two for the drivers side and two for the pass. side). Take your old front brake hoses off when you do the mod and just slap on the new modified ones.
I will get pics posted soon with some help from friends here. I will add comments after the pics are up.
THIS IS ONLY AN EXPLANATION OF HOW I DID THIS. IT IS YOUR DECISION IF YOU WANT TO TRY THIS ON YOUR OWN.
Finally.....the last photo is the front brace for the convertible. It weighs 19lbs. I need a photo of this on a vert so I can get an idea of how to install. Anyone?
1) Two Calipers
2) Two Caliper Brackets
3) Two Rotors
4) Set of pads
5) Two Banjo Bolts that fit the Saab Caliper (they bolt the brake line to the back of the caliper)
6) Four washers for those same banjo bolts (two for each side)
7) Four Grade 10.9 Metric Bolts (14mm diameter x 45mm long with a 2.0 thread pitch) these bolt the caliper bracket to
the back of the spindle
Two new front brake hoses for your G6
The calipers, brackets, rotors, pads, banjo bolts, and washers are all Saab parts available from a Saab dealer or from an auto parts store. The bolts need to be obtained from a good hardware supply location.
The first hurdle is that the bolts used by the G6 to bolt the caliper bracket (the caliper is first fitted into the caliper bracket and then the bracket gets bolted to the rear of the front spindle) to the spindle are smaller than the Saab ones. You need to get four of the bolts listed above which are larger and fit the Saab caliper bracket and will thread into it. You can just take the bracket with you to make it easier to find the bolts. It is VERY important that you get the exact ones and in the GRADE listed. The grade determines the strength of the bolt.
Next is you need to drill the two holes that are in the spindle a little larger so that those bolts will pass thru. It is only a slight increase in diameter. Not hard to do since the spindle is made of aluminum. Use a 9/16 drill bit. See the pics that I will get posted soon.
Another difference is the banjo bolts used to bolt the front rubber brake line to the back of the caliper. The Saab uses a larger banjo bolt. This is where getting the new front rubber brakes lines comes in. It will be easier to do this step BEFORE you start. Take the new brake hoses and drill the hole that is on the flat end a little larger so that the Saab banjo bolt can pass thru. This is probably the hardest part. You may want a machine shop to do this. It needs to be done cleanly, exactly centered, and the hole made only large enough to fit the new banjo bolt. The washers go on the banjo bolts. One goes on each side of the flat end of the hose (so you need two for the drivers side and two for the pass. side). Take your old front brake hoses off when you do the mod and just slap on the new modified ones.
I will get pics posted soon with some help from friends here. I will add comments after the pics are up.
THIS IS ONLY AN EXPLANATION OF HOW I DID THIS. IT IS YOUR DECISION IF YOU WANT TO TRY THIS ON YOUR OWN.
Finally.....the last photo is the front brace for the convertible. It weighs 19lbs. I need a photo of this on a vert so I can get an idea of how to install. Anyone?
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