2004 Saab 9-5 electrical problems

Filed May 10, 2025 · Electrical, Engine · NJ · fire

I purchased my 2004 Saab 9-5 in 2023. I was under the impression that everything was running and that drivability was proper. When I attempted to drive the automobile it would start, idle 7 minutes and stall. It would not start again for about 35 minutes. I tried to use it, and this behavior continued. Often, in traffic it would stall while I was moving at low speed, and moderate speed: Without warning, it cuts out and won't start for 40 minutes. I have spent money with my mechanic, over $1,000. I personally bought many parts: MAF sensor, fuel pump relay, fuel filter, and fuel pump. I replaced the Coolant Sensor. After all this the vehicle still stalls 5 minutes after warmup. If it drives to warm up, it stalls and won't restart for 40 minutes. After I replaced the Crankshaft Position Sensor, (CPS), it has never restarted. I bought 3, one a Bosch branded model, and It has never restarted. Many other drivers complain in forums, like Saab Forums, that they are experiencing the same problems. As you know, stalling at highway speeds can cause death. Clearly the problems with the Saab motorcars, produced, owned, and sold through General Motors, are something that poses a hazard, and should be repaired at GM dealership's expense. P.S. The vehicle's immobilizer device has caused my vehicle to not start at all. The key fobs have stopped functioning at all. I replaced the batteries, and they won't connect to the engine. The vehicle will crank, but no start. Battery runs down, with crank, but no start behavior. Can General Motors either: 1. replace the entire engine, 2. repair the "stall, no restart" situation, 3. moreover repair my seeming to be, "anti-theft system, no start" situation, called DICE/TWICEsystem, 4. achieving an actual fix for these older, but cherished sporting cars? Please check these links for confirming information: saabforums.com/forum/saab9-5-12/engine-turns-over--but-wont-start-9066/ www.saabcentral.com/threads/cranks-but-wont-start.689898/

Filed Jul 3, 2014 · Electrical, Engine · 70,000 miles · FL

I have owned a 2004 saab 9-5 sport combi wagon since 2006. Twice, over the last several years (2011, 2014), my husband and I have been on the highway and had an ignition switch incident where he was the driver and I was the passenger. In both incidents, I turned around to talk to my daughter (2011) and then daughters (2014) and inadvertently bumped the key in the ignition with my knee. The ignition switch is located in the center of the car by the console. It only took a slight tap of my knee and my car shut off while going at speeds of 75-80 MPH on the highway. Fortunately, both times my husband was able to put the car into neutral and get the car off to the side of the road.

Filed May 2, 2014 · Electrical · 64,000 miles · MD

Tl* the contact owns a 2004 sabb 9-5. The contact stated that while driving 75 MPH, the vehicle stalled without warning. The contact was able to restart the vehicle and took it to the dealer for inspection of the failure where the technician replaced the ignition module. The contact was made aware of a manufacturer's recall for the ignition switch but was advised that the vehicle was not included. The manufacturer was contacted. The approximate failure mileage was 64,000. Updated 10/23/2014*lj the consumer stated the check engine and no automatic warning lights would illuminate on frequently. Updated 8/10/2015

Filed Mar 14, 2014 · Electrical, Fuel system · 51,108 miles · MD

Tl* the contact owns a 2004 saab 9-5. The contact stated that while traveling various speeds, the vehicle suddenly stalled. The vehicle was taken to a private mechanic where it was found that the crank shaft position sensor, fuel pump, and the twice unit needed to be replaced. The vehicle was repaired but the failure recurred. The manufacturer was not contacted about the failure. The failure mileage was 51,108.

Filed Mar 6, 2014 · Electrical · 95,000 miles · VA

Tl* the contact owns 2004 saab 9-5. The contact stated that she was traveling 55 MPH with her purse on the passenger's side seat. The contact proceeded to exit the highway when the water bottle that was in her purse toppled over and struck the ignition switch, causing the vehicle to stall. The vehicle was not taken to the dealer for inspection or repairs. The manufacturer was not made aware of the failure. The VIN was not available. The failure and current mileage was 95,000.

Filed Aug 26, 2011 · Electrical · 46,172 miles · NV

A recall was previously issued for saab direct ignition cassette failures for model years 2000 through 2002. My 2004 saab 9-5 arc, which has 46,180 miles on it, had to have the di cassette replaced today due to failure. My model year should have been included in this recall due to the limited (less than reasonable) life of the part.

Filed Sep 15, 2010 · Electrical · 60,000 miles · NC

Tl* the contact owns a 2004 saab 9-5. The contact stated that when driving on the highway, the vehicle would suddenly shut down completely. The engine and electrical systems would turn off completely. The failure occurred several times. The vehicle was able to be immediately restarted when the failure occurred. The vehicle was inspected by an independent mechanic who stated that the ignition switch was most likely the cause for failure. The vehicle had not been repaired. The contact called the manufacturer who offered no assistance. The current mileage was approximately 74,00. The failure mileage was approximately 60,000. Updated 12/30/10 *bf updated 01/10/11*jb updated 3/31/14

Filed Oct 15, 2008 · Brakes, Electrical · 46,500 miles · NC

Purchased the car used 5/23/08 with 42,700 miles from saab dealership. Within a month the headlights worked randomly, check engine light would come on randomly. Called the dealership and was told that it wouldn't hurt anything and should it become more frequent, bring the car in. 8/18 took the car in to dealership when the light was coming on more frequently. Headlight relay replaced, engine light was due to a direct ignition cassette failure. Saab dealership ordered the part which was on national back order, part came in 10/9. Vehicle was taken in 10/6 due to steam coming from under the hood, temperature gauge never moved above the middle. Bypass valve replaced ($450 parts/labor). Vehicle has approx. 48,500 miles and is out of manufacturer warranty and repair is not covered under dealerships limited warranty. After an internet search for information relating to the di cassette failure I found that there was a recall for 2000-2002 models for the same issue. My vehicle is a 2004 saab 9.5 aero sedan.

Filed Aug 22, 2006 · Electrical · 5,000 miles · NJ

I have a 2004 saab 9.5 that I bought new on april 1, 2004. I discovered today for the first time that my backup lights are not working. Yesterday, I filed a complaint #10166145. This back up light problem is related. The hard plastic molded assembly on the drivers side of the trunk lid that is supposed to protect the wiring harness from damage is actually damaging and eventually cutting through all of the wires that pass through the assembly. Wires in my car began getting cut within 2 months of purchase and have continued. This assembly appears to be able to cut through about 8 wires leaving exposed wire in contact with each other and thereby disabling the cruise control, brake lights, reverse lights and electric trunk lock. This is not normal wear and tear - its a design fault. The wires seem to catch on the sharp edge of the plastic protector (!) that fits into the lid. They rub against this as the lid is open and closed. I believe this situation presents a potential electrical fire hazard and safety hazard and that the federal safety agency should immediately issue a recall on this item.

Filed Aug 21, 2006 · Acceleration, Electrical · 5,000 miles · NJ

I have a 2004 saab 9.5 that I bought new on april 1, 2004. From day 1 the cruise control was working erratically. Dealer said he could not replicate problem. Then cruise control stopped working. Then the electric trunk lock stopped working. I contacted the dealer telling it that even though I was now beyond the 50,000 mile portion of the 4 year warranty (of which only 28 months had elapsed) I wanted the trunk and cruise issues fixed along with a laundry list of items that were not addressed previously the last time I brought the car in under warranty. They have refused to address any of the issues. I found a site on the internet called saabnet. A particular post hit the problem on the head. Http://www.saabnet.com/tsn/bb/9-5/index.html?bid=125557 it said: turns out to be a badly worn wiring loom were the cables run from the car trunk into the trunk lid. 6 wires had broken through the insulation and two had completely snapped. This car is less than 3 years old!!!! This is not normal wear and tear - its a design fault. The wires seem to catch on the sharp edge of the plastic protector (!) that fits into the lid. They rub against this as the lid is open and closed. You can check to see if yours is ok simply by pulling off the protective rubber boot that attaches to the end of the plastic protector. I did the very simple check the poster recommended above by pulling the rubber cover back and was somewhat amazed to see 4 wires completely cut and the other 3 with broken insulators. As the poster on saabnet indicated, this is a design flaw and appears as if it could lead to fire. Looking further on saabnet, I see that many people have had this problem as it is discussed quite frequently. I believe this situation presents a potential electrical and fire hazard and that the federal safety agency should immediately issue a recall on this item.