Re: Clutch pedal falls to floor but pressure is good! New Info - Saab 9000 Bulletin Board - Saabnet.com


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Re: Clutch pedal falls to floor but pressure is good! New Info

Posted by thetallguy [Email] (#1698) [Profile/Gallery] (more from thetallguy) on Sat, 23 Feb 2019 19:19:33 Share Post by Email
In Reply to: Re: Clutch pedal falls to floor but pressure is good!, Simon S, Thu, 21 Feb 2019 18:07:20
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I have experienced the loss of the clutch pedal"feel" in this manner; when the Master cylinder fails the clutch fluid pushes past the seal and returns to the reservoir. No fluid loss is experienced. This failure, unfortunately, led to the replacement of the master cylinder followed by an almost immediate failure of the newly replaced master cylinder.This occurred several times over the space of four months. All/ most of the current replacement masters have the same hose barb failure. I have a friend with the same situation. His failed in the same manner. I have tried several brands (three in total). The issue: all these brands have a white-ish opaque hose barb (for hose from the reservoir) which fails within one week to three months. Replacing the master is not an easy job. After the third failure, I came up with this solution: I removed the third broken plastic barb-it pulls out of the upper seal with a little persuasion from a flat blade screwdriver. I then removed the OE barb (black) from the old original master cylinder and used that in place of the new. An inspection of the new VS the old reveals that the OD of the old is slightly less than the new but there is and additional collar on the top of the old barb which recesses very well into the new seal-in fact the fitment into the new seal looks to me to be superior...the collar is completely missing on the new barb even though the new seal has an obvious space for it. So far I have about 30K on this modification with no failures. My friend used his old barb and replaced it In-situ. Please keep this in mind when replacing the master.

One additional comment: my initial failure of the master clutch cylinder was precipitated by a failure of the master cylinder mounting bracket. The metal in the bracket actually started to tear away. The master cylinder was deflecting when the clutch was pushed in. This caused a miss- alignment of the master cylinder shaft (and very poor clutch "feel") which eventually did in the seal. I had to tie in the clutch bracket to the master brake cylinder housing to keep the clutch master from deflecting to the point of no fluid movement/compression. I used long bolts and large diameter spacers. Before it failed, I was also experiencing poor clutch "feel" and sometimes it was necessary to "lift" the pedal with my toe; however, I could still drive the car and I did have "pressure". Eventually the bracket fatigued beyond use, the master failed, as did the clutch return spring. This was followed by a new master cylinder install and the immediate problems of sourcing a well made Master as detailed above. Keep the old Clutch Master Cylinder Parts!!! Good luck!
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