Malfunction when declutching
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SERVICE INFORMATION
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Bulletin Nbr:
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411-2025
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Date:
...........
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February 1999
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Market:
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not US, CA
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Malfunction when declutching
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Saab 900 Sensonic M95-M98.
Clutch problems may arise after driving long distances which will be apparent through clutch failure or poor shifting performance, i.e. sluggish hydraulic function resulting in long delays in activation.
This is caused by the delivery hose (marked Dunlop, bumpy surface) emitting softener to the brake fluid. The softener affects all the rubber seals in the clutch system, making them swell. The inner tube of the 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 to the clutch hydraulics may also occur.
The fault should be rectified after customer complaint.
49 04 561 Slave cylinder repair kit
49 04 751 Slave cylinder, Saab 900 Sensonic
49 04 256 Delivery hose
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Important
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The delivery hose and master cylinder must be replaced when carrying out the following procedure.
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1.
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Remove the slave cylinder, see WIS, 4 Transmission, Sensonic.
If the complete slave cylinder assembly is to be replaced, go to step 14.
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2.
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Press out the locating sleeve and piston from the slave cylinder housing.
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3.
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Remove the circlip preventing the piston from travelling to far along the locating sleeve.
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4.
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Pull out the piston from the locating sleeve.
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5.
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Carefully cut away the rubber from the sealing ring in the locating sleeve.
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6.
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Pull out the sealing ring, use special tool (40) 260 147 020.
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7.
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Remove the remaining seals.
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8.
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Wash all components with non-fat detergent, especially where sealant has been applied. The surfaces abutting to the gearbox must also be cleaned.
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9.
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Fit new seals on the piston. Lubricate the seals, cylinder and piston with the grease included with ((16) 49 04 108).
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10.
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Press in a new seal inside the locating sleeve with special tool (16) 78 41 067 and lubricate it.
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11.
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Fit the O-ring on the locating sleeve to seal against the slave cylinder housing.
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12.
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Slide the piston onto the locating sleeve and fit the circlip.
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13.
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Put the locating sleeve with piston into the slave cylinder housing.
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Note
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There is no need to press in the locating sleeve completely as it will be pressed home when the slave cylinder is fitted to the gearbox.
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14.
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Clean the surfaces on the slave cylinder to which sealant is to be applied.
Clean also the corresponding surfaces on the gearbox.
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Important
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Steps 14-18 must be carried out each time a slave cylinder is fitted.
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15.
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Apply liquid sealant Loctite 638, part no. (16) 49 04 090. Allow the sealant to spread for a minute or so.
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16.
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Fit the green seal onto the rear of the slave cylinder, use Loctite 638, part no. (16) 49 04 090, to keep the seal in place while fitting.
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17.
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Lubricate the clutch plate seal with transmission fluid.
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18.
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Fit the slave cylinder:
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-
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Apply threadlock (16) 74 96 284 to the bolts.
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Tighten the bolts alternately so that the locating sleeve is pressed home in the cylinder.
Tightening torque: 10 Nm (7.4 lbf ft)
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-
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Fit and tighten the delivery pipe and bleed nipple.
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-
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Fit the release bearing.
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19.
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Change master cylinder, see WIS 4 Transmission, Sensonic.
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Warranty/Time Information
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Failed Object: 41230, 41240, 41221
Fault/Reason code: 72
Location code: 09
Repair/Action code: 01
Time:
41230 = 0.8
41240 = 0,7 + removal 47100
41221 = 1.5
