QuestionMy clutch burned up on my 91 Saab 900 (non turbo). Is this a DIY project for someone who has little experience and what all would I need to do this job. Secondly, where could I get info/directions to complete this?
Thanks
AnswerSorry for taking so long. A work emergency has kept me away for the last week.
This is proby not the best DIY for someone with little experiance. On the other hand who cares if you screw it up. Swallow your pride and take it to your local mechanic if you cant fiqure it out. All it will cost you is a 6-pack to a friend to help you tow it. I personally would try if I were you. Everything that I know about the automotive world is all self taught. I would also recommend looking at the various online Saab forums for additional guidance. I have also pasted the procedure below.
1. Disconnect the negative battery cable1. .
2. Remove the hood assembly. Remove the preheater hose and clutch housing cover.
3. Install the spacer 83-90-023 or equivalent, between the clutch fork and the diaphragm spring. Keep the
clutch pedal depressed when the ring is being installed.
4. Unhook the spring clip and remove the cover located in front of the clutch shaft.
5. Remove the clutch shaft plastic propeller.
6. Remove the clutch shaft by means of a M8 bolt installed in the shaft end and tool 83-93-175 or
equivalent. Withdraw the shaft as far as possible.
7. Remove the clutch slave cylinder retaining bolts.
Remove the clutch retaining bolts and remove the clutch, clutch disc and the slave cylinder complete
with the clutch release bearing. Be sure the slave cylinder sleeve is not damaged by the clutch during
the removal procedure.
To install:
8. Before re-assembling the clutch, check the condition of the clutch shaft seal located in the primary
drive chain case and the condition of the support bearing in the flywheel.
9. Install the pressure plate, clutch plate and slave cylinder with release bearing as one unit onto the
flywheel housing.
NOTE: Lubricate the clutch shaft splines sparingly with molybdenum disulfide paste.
10. Push the clutch shaft into engagement with the clutch plate splines and into the support bearing in the
flywheel. Install 2 of the pressure plate bolts, but do not tighten them.
11. Tap in the clutch shaft so it is locked by the snapring in the primary drive sprocket.
12. Install the slave cylinder to the primary chain case. Apply thread sealing compound to the bolts.
13. Install the plastic propeller to the end of the clutch shaft. Install the seal, cover and wire clip in the front
of the clutch shaft.
14. Bolt the pressure plate unit to the flywheel.
15. Have an assistant press down the clutch pedal and remove the spacer ring which was installed during
removal.
NOTE: Do not depress the clutch pedal further than necessary to remove the spacer.
16. Pull the movable locking ring towards the slave cylinder housing while the clutch pedal is depressed.
17. After the clutch is installed, push the plastic sleeve against the release bearing, as required.
18. Install the flywheel housing cover and preheater hose.
19. Refit the hood. Connect the negative battery cable.
Good luck,
Richard
