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Clutch replacement - LONG
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Posted by skibumm100 [Email] (#3255) [Profile/Gallery] (more from skibumm100) on Tue, 29 Jul 2025 08:19:14 Share Post by Email
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I had a clutch failure on the road to SOC 42 in NJ. Initially the clutch pedal went to the floor when shifting into 2nd leaving a light. I coasted to the side of the road. I reached down and lifted the pedal back up and it returned. The clutch release point changed from near the top to near the bottom. It kind of worked OK and I limped it to the hotel about two miles away. The clutch engaged and disengaged. I checked in and came back out in the morning. I checked operation and it worked OK, not great. I was hoping I could limp it to the meet and, hopefully, back home. I figured I better get some fresh brake fluid in case the fluid was leaking somewhere, just as a precaution. A couple blocks away I stopped for a stop sign. When attempting to pull away The clutch pedal came up but the car didn't move. No movement in forward, reverse, or any gear. The RPM's didn't drop in gear with the pedal out. The clutch went from working OK to not working at all. Clutch disks don't normally die that way. They start slipping first. I thought it might be the master cylinder, but leaving the car for hours, I can still put it in gear, not touching the pedal, and start it in first gear. It's like the car was in neutral. My initial thought is that the slave cylinder seal failed and has jammed the piston in the out position. The disk is smoked, based on all of the clutch material in the inspection opening. I had the car towed to a local transmission shop to see if they could get the parts to repair it. They couldn't. The only lead they had was a LuK clutch at their wholesaler. It turns out that it was shown in the computer, but had probably been thrown out.

In my search for clutch parts I found that Sachs no longer manufactures a clutch for late model 9000's. I don't think LuK does, either. The OEM slave is no longer available. The OEM master is no longer available. SKF no longer makes the clutch release bearing. Nobody seems to have any NOS clutches.

The best options seem to be to rebuild as much of the stock stuff as possible....OEM slave and master cylinder kits are still available. I may have to use a used pressure plate or have one "rebuilt". As far as disks, they can be inspected and relined. I have also heard that the early 9-5 clutch disk will work in the 9000. The pressure plate will not. I don't know about the slave cylinder. I have not found an OEM clutch release bearing anywhere. RBM in France has a "European quality replacement".

I'm OK using a rebuilt clutch and disk, but not a used clutch release bearing. In the end, I may have no choice.

I will report back on the failure mode of this debacle once I get the car apart. 

_______________________________________
long-time listener, first-time caller
Saab glutton for punishment
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