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Date: 16 Apr 2000 18:57:17 GMT
From: stephydronopsamcomNOSPAM (StepHydro)
Subject: More 900s clutch grief...sigh!   (long, sorry)


All right all you fine helpers, I finally got the clutch replaced in my daughter's 1988 900s 16V, 5spd. It took me longer to do this clutch job than is did to remove the engine, rebuild the transmission, and replace the engine unit. Miserable job, which didn't have sufficient clearance, even with the 4mm thick holding ring I made. But I did get it on. Now, there is a serious operational problem.When I release the clutch, there is a great "grab and lurch" just as the clutch starts to engage. Here is the cause: On the slave cylinder body, there is a plastic sleeve with a large circlip. The device serves as a wear indicator for the clutch disk and I suppose as a dist protector for the body of the slave cylinder. When the clutch pedal is depressed, the slave cylinder body carries this sleeve out past the nose of the slave cylinder body. The extension (or gap) is on the order of 2.5mm when the pedal is fully depressed. When the pedal is released, the plastic sleeve comes "forward" and contacts the nose of the body. At this point, quite a bit of additional release of the pedal is necessary to allow the pressure plate diaphragm spring to overcome the grip of the circlip. When that happens, the pressure plate moves quickly, taking up all the stress built up by the diaphragm spring, and the car lurches. Now, in taller gears, one can gingerly depress the pedal and avoid the long travel that causes the glitch. However, starting off, it is so disruptive that I don't think my daughter will be able to drive it safely. I am certain the when the plate wears enough to allow the sleeve to withdraw permanently forward, then the lurch will go away. Finally, it appears that the slave cylinder assembly pushes the sleeve too far forward. I have thought through the assembly process and assured myself that the exposed end of the piston *was* sticking through the sleeve and that that end of the piston was engaged in the rubber "teeth" of the release bearing inner surface. That piston has a step on its (toward the engine) outside diameter. The shoulder of that step engages the palstic sleeve. the sleeve moves to and fro as the pedal is pushed and released. I can see that if the sleeve was back (forward, that is :-) against the nose of the slave cylinder body, this wouldn't happen. However, when I tried to get it back there prior to assembly of the whole clutch, the force required seemed enough to break the sleeve. should I have gone ahead and forced it? If so, can that be done in situ?? Help is greatly appreciated in advance. Cheers/Don Carron Rockford TN USA

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