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Sticking clutch cable/clutch malfunctioning, RHD

SERVICE INFORMATION
Bulletin Nbr: 410-1865
Date: ........... FEBRUARY 1998
Market: ACCORDING TO LIST
Sticking clutch cable/clutch malfunctioning, RHD


Service Directive 104 57

Cars in stock must be rectified before delivery.

Cars already delivered should be rectified next time they are brought in for regular servicing or repairs.

Cars affected

All right-hand drive Saab 900 M94-M97

Background

The driver may feel that the clutch cable is sticking. The cable may also break.

This is rectified by replacing the cable with a new type and repositioning the cable in the engine bay.

Parts required

49 03 639 Clutch service kit, 4-cyl.

49 03 647 Clutch service kit, 6-cyl.

87 81 718 Silicone grease (One pack is sufficient for five cars).



Clutch cable, 4-cyl. or clutch cable, 6-cyl.

Bottom mounting

Nut (2 pcs.)

Screw M8 x 60

Washer

Spacer sleeve

Top bracket

Screw M6 x 20

Procedure


1. Remove the existing clutch cable, see ”4. Manual gearbox, Adjustment/replacement, Clutch cable”.

2. Remove the existing mounting on the gearbox mating face.

3. Fit the mounting in its new position with:


Screw M8 x 60

washer

spacer sleeve

nut.

Tightening torque 24 Nm (18 lbf ft).

4. Fit the bottom mounting with nut on the existing screw on the gearbox mating face. The new mounting must fit against the top edge of the existing mounting, see illustration.


Tightening torque 24 Nm (18 lbf ft).

5. Fit the new clutch cable (for 4-cyl. or 6-cyl.), see ” 4. Manual gearbox, Adjustment/replacement, Clutch cable”.

Lubricate the cable mounting on the clutch pedal and clutch arm with silicone grease 87 81 718.

6. Remove the mounting fitted with the middle screw on the brace between the MacPherson struts.


7. Refit the screw.

Tightening torque 8 Nm (6 lbf ft)

8. Fit the mounting to the top bracket with screw M6 x 20. Do not tighten the screw.


9. Place the bracket on the brace and fit the existing screw.


10. Place the cable in the mounting.


11. Tighten both screws.

Tightening torque 8 Nm (6 lbf ft)

12. Make sure the drainage from the bulkhead partition space runs behind the cable but in front of the power steering hose, see illustration.


Warranty/Time information

See separate information.