mystery hydraulic clutch problem, 2002 Viggen - Saab NG900 & OG9-3 Bulletin Board - Saabnet.com
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mystery hydraulic clutch problem, 2002 Viggen
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Posted by Skipfinder [Email] (#1322) [Profile/Gallery] (more from Skipfinder) on Mon, 27 May 2013 19:10:40 Share Post by Email
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I'm not a newbie and have turned my own wrenches since dirt was new. I've owned three 900 convertibles, a 2004 convertible, and now own two 2002 2-dr Viggens. One of them is giving me untold grief with the clutch hydraulics.

One day without warning the clutch pedal went to the floor. The fluid was above the clutch reservoir threshold and there are NO leaks. Bleeding the system will put everything back in order, but the problem returns immediately. Air is getting into the system and I'm not sure of the source or the reason.

I have the tools and experience to ensure that ALL air is removed from the system and have a hard pedal and full clutch disengagement. I replaced the master and the flex line just because they are so easy and to rule them out. I have adjusted the pedal travel via the pedal stop to ensure that there is no pedal over-travel beyond what is required for full clutch disengagement.

Here's what I don't understand. When the pedal is released the pressure plate fingers force the slave back, thus expelling fluid back to the master. At the last inch at the top of pedal travel the master bore is exposed to the reservoir. At no point should there be a vacuum in the system to pull air past the slave seals or the flex line o-rings at the top of the transmission, but air is definitely getting in.

I'm reluctant to replace the slave when the one on the car is not leaking, and a search of the 'net shows that this problem is endemic but with no clear solution. Believe me when I tell you I've tried every trick I've read about.

Anyone feel like tackling this? I feel like I'm missing something.

->Posting last edited on Mon, 27 May 2013 19:12:48.

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