93 Convertible Clutch Master Replacement Experience - Saab 900 Bulletin Board - Saabnet.com
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93 Convertible Clutch Master Replacement Experience
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Posted by eric in vermont [Email] (#2058) [Profile/Gallery] (more from eric in vermont) on Mon, 3 Jun 2019 16:52:03 Share Post by Email
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Thanks to the extremely helpful advice from this group, I was able to replace the clutch master and clutch flex line in my new '93 900 Convertible. I wanted to share a few things about the experience that may be helpful to other 900 newbies and reinforce some of the advice.

1. Diagnosis. little or no clutch, no leaks. The board said it was definitely the master- "that's how they fail". Sure enough, when I got the master out and removed the guts, it was shot and full of nasty black fluid.
2. Parts Source. I decided to order Beck Arnley parts from Rock Auto. I got the master, slave and flex hose for about $100 or so.
3. Knee Panel Removal. There's a great youtube video from a guy named Terje Normann showing every step. Here's the link:

https://www.youtube.com/watch?v=7Odmit6rQRg&t=449s

One difference for me: I pulled out the drain tubes on each side so I could get better access to the two stinking bolts way down in the wheel wells. I also put tape on the bolt heads so they were stuck firmly in the socket when I went to reinstall. Amazingly, I didn't drop them once! A miracle!
4. Flex Hose. I used a 1/2" crows foot filed to 13mm to loosen the fitting on the master. But then I found I could fit my hand in around the alternator and swing an open end wrench. Seemed to work better for me.
5. Clutch cover. It fought me and I hated it. But the advice was to twist and pull toward the driver's side with NO FEAR, so I did and it relented. When I went to reinstall, it renewed it's fight with a vengeance. Then I got the bright idea to pull the intercooler and air filter housing and it made it much easier. Should have done that from the start.
6. Installation of the master and the flex hose were no problem with all that stuff out of the way. Good advice to thread the flex hose on the master BEFORE tightening down the master.
7. Master Fill Hose. Original was junk. I ended up using some motorcycle Tygon 2375 brake tubing I found on Amazon. It comes in 1 foot lengths- get the 1/4" diameter stuff.
8. Brake Switch. I bumped the brake light switch under the dash and it fell to pieces. I ordered a Beck Arnley 201-1105 one from Amazon for $5 and it worked like a dream. It only comes with one nut, so you need to get another stop nut (metric threads). It's a bit longer than the original but fits fine. It even has the right connections.
9. Bleeding. I ordered a 3 pack of nice 150mL syringes from Amazon and reverse bled the system. As recommended, remove old fluid from the master reservoir and dispose. Then push new fluid through the slave bleeder until the reservoir fills. I pushed two syringes worth until it all looked nice and clean. I used Valvoline DOT3/4 bought locally. Once that was done, I had my wife come out and give two pedal pushes, bleeding at the slave the normal way.
10. Slave. Bought it. Didn't use it. Why not? No leaks and new fluid. Maybe a mistake. The board advice was mixed. So I have the new one.
11. Results. Over a week and clutch action is excellent. On Saturday a friend borrowed the car for their daughter's wedding. The newly married couple drove from the church to the reception in it.

Thanks again for all the help. Amazed at the fast response and activity on the 900 board. Things over on Vintage and Sonett are pretty quiet these days.

Maybe see some of you at the Saab Jamboree at Endless Mtns PA this weekend??? 900's are welcome!!!

https://endlessmountainssaab.com/

eric in vermont

PS: As a 900 newbie, I'll be having many more questions!


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