Clutch System - Hydraulic Contamination
SI. No. 410-2O26PI No.
Date: August 1999
Distr. all
9000
Malfunction when declutching
Cars affected
Saab 9000 M92- (gearbox no. D41693-).
Background
Clutch problems may arise in which the clutch pedal:
1. may become hard to depress
2. may require more travel before the clutch disengages
3. may not be possible to declutch at all
This is caused by the pressure (delivery) hose (marked Dunlop, bumpy surface) emitting plasticizer to the brake fluid. The plasticizer affects all the rubber seals in the clutch system, making them swell. The inner tube of the pressure (delivery) hose may subsequently crack and small particles of rubber collect in the feed holes of the slave cylinder, blocking the flow of fluid.
Leakage of transmission fluid into the clutch hydraulics may also occur, contaminating the clutch system.
The fault should be rectified after customer complaint
Parts required
49 04 546 Slave cylinder repair kit, Saab 9000 M90-93 (CA: 30581627)
49 04 561 Slave cylinder repair kit, Saab 9000 M94-(CA: 30581629)
49 04 553 Gearbox sealing kit, Saab 9000 M94-(CA: 30581628)
49 04 579 Slave cylinder, Saab 9000 M92-93 (Gearbox no. D41693-) (CA: 30581630)
49 04 587 Slave cylinder, Saab 9000 M94- (CA: 30581631)
Pressure (delivery) hose (dependent on steering wheel position and model year - see EPC for specific model year parts application)
Master cylinder feed (braided) hose (see EPC for specific model year parts application)
Procedure
Important
Drain and flush the whole system thoroughly. Clean the fluid reservoir and replace the feed (braided) hose from the reservoir to the master cylinder. Then, replace the master cylinder and pressure (delivery) hose. See EPC for specific part number application.
An alternative for right-hand drive cars is to replace the seals in the master cylinder
1. Remove the slave cylinder, see 4 Clutch system. If replacing the slave cylinder, go to step 13.
2. Press out the locating sleeve and piston from the slave cylinder housing.
3. Pull out the piston from the locating sleeve.
4. Carefully cut away the rubber from the sealing ring in the locating sleeve.
5. Pull out the sealing ring, use special tool (40) 260 147 020.
6. Remove the remaining seals.
7. Wash all components with detergent, especially where sealant has been applied. The surfaces abutting to the gearbox must also be cleaned.
8. Fit new seals on the piston. Lubricate the seals, cylinder and piston with the grease included with ((16) 49 04 108).
9. Press in a new seal inside the locating sleeve with special tool (16) 78 41 067 and lubricate it.
10. Fit the O-ring on the locating sleeve to seal against the slave cylinder housing.
11. Slide the piston onto the locating sleeve.
12. Put the locating sleeve with piston into the slave cylinder housing. making sure it is fully seated.
13. Clean the surfaces on the slave cylinder to which sealant is to be applied.
Clean also the corresponding surfaces on the gearbox.
Important
Steps 13-17 must be carried out each time a slave cylinder is fitted.
14. Apply liquid sealant Loctite 638. Allow the sealant to spread for a minute or so.
15. Fit the green seal onto the rear of the slave cylinder, use Loctite 638 to keep the seal in place while fitting.
16. Lubricate the clutch plate seal with transmission fluid.
17. Fit the slave cylinder:
- Apply threadlock (16) 74 96 284 to the bolts.
Tightening torque: 10 Nm (7.4 lb ft)
- Fit and tighten the delivery pipe and bleed nipple.
- Fit the release bearing.
Warranty/Time Information
Failed Object: 41230, 41240, 41221
Fault/Reason code:72
Location code: 09
Warranty Type (US): Normal warranty rules apply
Repair/Action code: 01
Time:
41230 = 0.9
41240 + removal 47100
41221 = 0.6
(CA: C4660)
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