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Successful clutch replacement, misc info (long)
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Posted by White Vampire (more from White Vampire) on Fri, 31 May 2002 06:16:23 Share Post by Email
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I first started on replacing the original clutch on my '85 900S two days ago now. The clutch kit was bought from eEuroparts, and is the turbo clutch, I believe. The pressure plate is *much* stronger than my old clutch.

Took off the hood, removed tubing to get to assembly cover, removed the right fan, and fought to get the cover off. That in itself is a task. After that, I shoved spark plug wire in around the pressure plate, but it turned out not being far enough in. With the help of SAABnet, I figured out the plastic piece twisted off the new of the input shaft, and used a bolt for leverage to pull it out. I also used a board to protect the radiator.

Much later, after fighting with the assembly and slave cylinder, they were finally removed with the help of my dad. After some failed attempts of getting the new pressure plate's teeth to stay down, I called it a night.

A 'house support' jack was used to force the new pressure plate down under a joist (IE. house) and a 6ga (approximately) wire was inserted around the inner circumference of the pressure plate.

I had begun removing the inner shaft seal the night before, with failed attempts using a screw driver. It was in tight. Per the suggestion of SAABnet, I ended up using a torch. It took a bit to work out, but after holding the torch on it for a while it slid out with a screwdriver. I used teflon grease around the edges and then tapped the seal in with a socket and hammer.

After that, I started trying to get the clutch assembly and new slave cylinder in. After a few failed attempts, I decided to read up (and post) on SAABnet regarding possible alternate methods and the way the clutch disk faced. When I came back out, my brother had managed to get it in. Albeit, with the pieces positioned incorrectly, but we managed to get it in correctly with some work. It was angled in from the right .. we had the assembly to the right somewhat, worked the slave in, and then lined it all up properly. I had the smaller diameter circle on the clutch plate facing towards the flywheel.

Tapped the input shaft in, reassembled the snap clip, screwed on the clutch assembly to the flywheel, and screwed in the slave cylinder. Bled the clutch.. and then I doubted the way that the clutch plate was facing, and went to do some research. With two conflicting posts, both saying the opposite things, I gave up. When I ended up trying to start the car to test it, it immediately cut off, I hopped out and discovered a broken fuel line! To the parts care.. carefully switched, and it starts. Some problems shifting, it shifts but I end up figuring out it is losing pressure. Tighten up the lose fluid line, and it works beautifully. I am simply overjoyed at this point.

I fight and force the assembly cover on, screw fan on, restore tubing and intake, and the rest of the last minute touches.

A shower, and a drive.. it works beautifully. My fluid is low, which is causing a bit of inconsistancy, as I was not able to bleed again. I will pick up some more fluid and re-bleed soon.

I would like to give a lot of credit to SAABnet and my family for the help that was given. It helped me through some frustrating spots.. hopefully this will help someone else.

New dash, headliner, various interior tweaks, replaced exhaust (and heat shield), brake master cylinder, clutch (and related parts), and various other things along the way.. I am losing track now. Between Bentley and SAABnet, it has been going great.

Exhausted.. I pulled an all-nighter to finish this. Please excus any grammatical errors, as I lack the focus to proof read.

Regards,

White Vampire\Rem

posted by 170.215.144...
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