Date: Mon, 27 Mar 2000 00:29:09 +0200
From: Robert Brown <>
Subject: Re: Saab clutch, 4 mm clearance and it still won't come out

Hi, Not sure if I've interpreted your story correctly, but is it possible that you're trying to do the job without either: 1. Removing the splined axle that runs through the centre of it all (remove the spring clip and dustcap at the very front of the gearbox, screw in an 8mm bolt to make it possible to pry the axle forwards with a crowbar. Leave the axle hanging at the edge of the radiator), ... or ... 2. Sliding the slave cylinder out (held in by three allen key bolts) at the same time. Clutch doesn't come out otherwise. Be sure that the slave cylinder piston doesn't travel too far aft when you pull it all apart. You don't have to disconnect the hydraulics, as long as you remove the clips that hold the clutch line to the bodywork. Use Loctite on the three allen key bolts when reassembling. If I've mentioned the obvious by suggesting the 2 points above, then accept my apologies. Delete this mail ;-) Otherwise, I hope your chances have improved . . . Good luck, Robert Gothenburg (1983 900 GL, 1999 9-3 200) StepHydro wrote: > Well, > > I made a 4 mm thick ring tool that would fit under the pressure plate housing > abutments, thus holding the diaphragm spring fingers depressed. This ended up > giving me 5+ mm clearance between the front surface of the throwout bearing and > the spring fingers...nearly 6 for most fingers. > > The %%$#%*&#$ thing still won't come out. > > I move the throwout bearing out of its spigot > I pull up and to the right with the whole moves nearly two inches > off-center. > The slave cylinder lacks 6 mm clearing the rear of the transfer case housing. > The clutch plate hub (sticking aft into the center bore of the flywheel) > catches on the inner bore of the flywheel. > > No combination of moves I can come up with will free the assembly. If the front > spigot on the salve cylinder were 4 mm shorter, I could force it past the > fingers of the diaphragm spring. > > Can anyone suggest why *every other* Saab in the world will come apart with the > regulation 4mm clearance, yet mine won't separate even with nearly 6?????? > > All help greatly appreciated. I have been at this for over a month now (off and > on, of course). I am an ex motorcycle and sports car road racer who has done > his own mechanics since around 1957. I have removed the engine from this Saab > and rebuilt the transmission. Why is this so difficult? > > TIA/Don Carron

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