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Hello PTH. Your problem is intriguing and I don't recall encountering anything similar. Eric's reply was very pertinent and your answers filled in some blanks. I've pondered some and come up with one approach you can try. Your problem of difficult shifting is not uncommon by itself, but the temperature factor is the odd part.
The usual cause of hard shifting as you describe it is that the clutch is not disengaging fully with pedal down. This will affect first and reverse most severely but you will find it affects other gears as well. I cannot think of a scenario that puts your issue inside the transmission.
My approach is to try to measure the pushrod throw at the slave cylinder when you operate the clutch pedal, and see if it is different cold and warm. If it is less when warm, resulting in incomplete disengagement, the problem is isolated to the hydraulic system. If it is the same cold and warm, the problem is in the bell housing or (unlikely) in the transmission.
This is not a movement that is routinely measured and you will have to be inventive if you want to attempt it. Eyeball accuracy will be inadequate, because the difference between full and incomplete disengagement at the slave pushrod is probably just a few thousandths of an inch. You will need to set up a dial indicator (Harbor Freight probably has a cheapie) in a way that you can repeatably measure pushrod extension cold and warm to see if it changes. The details I leave to your ingenuity.
Two common reasons for incomplete disengagement are cracking of the firewall near the clutch master cylinder, easily seen and common on certain vehicles but not Saabs that I know of; and floor mats creeping up under the pedal so it cannot go down as far as it should. Hope this helps.
posted by 75.147.23...
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