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Old 02-05-2016, 04:15 PM   #1
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2002 9-5 Aero Wannabe

As some of you may know, I got a 9-5 with a slipping automatic transmission in the Summer of 2014 for $500. The plan when I got it was to flip it with a buddy and try and turn a profit. Over the time it's taken me to get it road worthy, The need for another vehicle in my family presented itself, so I gave it to my brother. He tours with a musician a good portion of the year, so I get the pleasure of treating it like another one of my cars

I am trying to nurture his interest in tinkering with cars while also satisfying my addiction.

The day I got it in Atlanta:



The replacement Automatic slushbox:





finally got it driving with a few quirks -- Take it on a road trip to Atlanta, stock linear turbo bites the dust, and quickly. I actually had the fire department called on me I was burning so much oil.

Picture from the rescue mission.



New TD04 to replace stock turbo, and phase one of making it an aero.



That one time my AC drains were clogged and the entire car flooded. Good times.



Built some better drains



Got some new wheels (And beer)



Some guy rear-ended me in a parking lot. He paid for a new trunk lid from a parts car. I ended up returning with one that had a spoiler and was in better shape then the one I intended to buy. Oh, and he paid for my gas.




Bought an 2003 + Aero front bumper and some aero side skirts (hard to see in pics of black car in shitty lighting)





I bought a set of uninstalled Koni's and Vogtland springs for it in December. But they belong on a 98-01 9-5. So, I'm actively finding a way to adapt them. (I do stupid stuff every now and then.)




Some glory shots:





That pretty much brings us up to date... The transmission is generally fine. Every so often, it'll throw a code for the converter and will start to slip... but, I've found that if you key off, key on, then all is well for another couple hundred miles. Obviously some electrical gremlin that I don't care much about finding. I've grown to love this car. Probably one of my more rewarding projects that I've had.

I plan to one day manual swap it (already have all necesary parts, minus a clutch.) But, I'm going to wait until either the auto fails again, or a I have a bunch of spare time. Taking bets on which one of those happens first.
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-1992 9000 T5
-1994 9000 Aero
-2004 9-5 Aero Wagon - Espresso Black
-2004 9-5 Aero Wagon - Glacier Blue

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Old 02-05-2016, 04:22 PM   #2
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Things to come:

-Install custom 3 inch DP
-Retrieve and install black aero interior
-Adapt lowering kit
-Tint
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-1992 9000 T5
-1994 9000 Aero
-2004 9-5 Aero Wagon - Espresso Black
-2004 9-5 Aero Wagon - Glacier Blue
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Old 02-05-2016, 04:48 PM   #3
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Nice!

You may find it a waste of time to adapt the lowering kit (I think you'll have to swap out a bunch of front hub/knuckle stuff?).

My 02 was a base model to start. But it's lowered on eibach's with Koni's, has all the aero skirts and lip spoiler, I run RK1's in the summer, it's got aero interior and steering wheel and leather shift knob/boot... you'd never know it wasn't an aero Except I have opted to keep the 2.3t badge on the back (it actually still has the GT17 pulling strong, but I have my 18t TD04 sitting on the shelf form y old Aero). Everyone is dying to find a 5spd Aero wagon, but it'd probably be easier to go this route and "Aero" a base model w/ 5spd stick.

This is a cool project. Nice work keeping an older, solid car on the road!
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Old 02-06-2016, 08:23 AM   #4
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Trunk loaded down, lookin low.



Post wax



Better pic of the new aero bumper. Sans foglights. Anyone have foglights for sale?



Lurking in Atlanta

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-1992 9000 T5
-1994 9000 Aero
-2004 9-5 Aero Wagon - Espresso Black
-2004 9-5 Aero Wagon - Glacier Blue
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Old 02-06-2016, 08:29 AM   #5
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Quote:
Originally Posted by Cark View Post
Nice!

You may find it a waste of time to adapt the lowering kit (I think you'll have to swap out a bunch of front hub/knuckle stuff?).

My 02 was a base model to start. But it's lowered on eibach's with Koni's, has all the aero skirts and lip spoiler, I run RK1's in the summer, it's got aero interior and steering wheel and leather shift knob/boot... you'd never know it wasn't an aero Except I have opted to keep the 2.3t badge on the back (it actually still has the GT17 pulling strong, but I have my 18t TD04 sitting on the shelf form y old Aero). Everyone is dying to find a 5spd Aero wagon, but it'd probably be easier to go this route and "Aero" a base model w/ 5spd stick.

This is a cool project. Nice work keeping an older, solid car on the road!
Eh, I found a pair of steering knuckles for $100. I'm suspicious that I need a new wheel bearing on the car as it sits... So as long as I can figure out the right combination of stuff, I'll end up adapting it. I saved myself a couple hundred by buying the way I did.

My GT17 pooped itself hard. The exhaust side turbine was rolling around in the housing when I took it off the car.

I agree, I'm all about finding cars that need a little work and making them nice. I've really enjoyed this transformation. It doesn't bother me at all that it's not a real "Aero"

I forgot to mention that I also have the sport wheel and aluminum dash fascia. But I'm waiting to install that until I source a black dash to match my black interior.
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-1992 9000 T5
-1994 9000 Aero
-2004 9-5 Aero Wagon - Espresso Black
-2004 9-5 Aero Wagon - Glacier Blue
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Old 12-04-2018, 07:06 AM   #6
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I'll restore this old thread even though it's useless with the original pictures missing.


Anyways, the car sat for almost a year with BUS communication issues when my brother and I tried to swap the dash from tan to black, the last step in swapping the entire tan interior to black.

Finally got it back up and running last week.

So now it has a black Aero interior with a black dash from the 04-05 models. Also got the aluminum fascia piece. It looks so much better than the car did originally. I think it cost around $50 for the dash and aluminum piece from the junkyard

Picture of the new dash - Forgive how dirty the car is

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-1992 9000 T5
-1994 9000 Aero
-2004 9-5 Aero Wagon - Espresso Black
-2004 9-5 Aero Wagon - Glacier Blue

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Old 12-04-2018, 07:26 AM   #7
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Some old pictures to replace the missing ones:







Halfway through the interior swap:







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-1994 9000 Aero
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-2004 9-5 Aero Wagon - Glacier Blue
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Old 12-04-2018, 07:38 AM   #8
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Wow, that's a FULL swap, I would just swap the front seats, steering wheel and call it good!

I miss my '02 linear wagon. It was a 5 spd, had aero lip and skirts, aero seats w/ sport wheel, lowered suspension and aero brake set up. Actually kept the little GT17 but had a GS 3" DP and BSR cat back. It was the perfect setup for me! Super quick spool, great fuel economy. The rust had gotten it pretty bad, so I got my '08, sold the '02 to a co-worker last winter for $500. He's put 20k on it and hasn't had to do a single thing. Go figure.
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Old 12-05-2018, 06:09 AM   #9
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Good work! I'm very partial to dark interiors, myself. The light gray leather in my 9000 is about as not-black as I can handle so I can understand why you'd do this.

A looong time ago I helped my dad swap his 9000 CS from beige to full black Aero interior, dash swap and all. It was a ton of work, and we had the benefits of no computers to reprogram and the parts car sitting next to the car being swapped. Props for doing this with junkyard parts.
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