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When I purchase my first Saab at the beginning of the year I found that the cruise control was not working. Turned out that a new clutch cable had been fitted and the clutch pedal return spring had been broken. The Cruise Control would not engage due to the clutch pedal switch not being made. I made a clip that attached the broken end to the clutch pedal. Very difficult working under the dash !#$!!
The clutch operation has been heavy and operating very near the floor – not very good driving in city traffic. I decided to order from my local Agent a new return spring and they said it would have to come from Sweden. To my surprise they rang after 10 days to say it had arrive and it was $15.60NZ (Approx $7.80US).
This time I pulled out the driver seat and that made the whole operation a lot easier. I took out the clutch pedal to replace the broken spring. While it was out I decided to make a plastic (PETP) bush to hold the coiled part of the spring. This was a press fit on the pedal shaft boss and had a shoulder to keep the spring compressed axially as it’s slightly too long. I was aware to make the OD of the bush to have enough clearance to prevent the spring from being spring bound when the pedal was fully depressed.
I had seen a Saab Bulletin 412-9016 (Correcting a Customer complaint regarding clutch pedal play). I pulled out the clutch cable end out of the firewall and found the rubber bush that fits into the hole was cut and half of it missing. I decided to cut it off and just retain the buffer flange part of it. I then turned up another PETP bushing to centrally hold the cable in the firewall hole. On this bushing I decided to put another flange so as to increase the outer cable length by about 4mm. So the order of parts put onto the cable outer housing was the original cut down rubber bush, my new PETP bush followed by a original metal washer. Putting back the pedal was a breeze as the spring was retained on the pedal boss and all I had to do is engage the fixed spring end and the clutch pedal top end into the clutch cable end fitting. I lubricated the cable connection and the clutch pedal shaft with CRC White Lithium grease as per Dean’s suggestions. I then got a strong cord and placed over the top of the clutch pedal shaft and hooked it around the spring and pulled as I guided the spring and clipped it over the gap where the cable end attaches to the pedal assembly.
After putting all the under dash covers back and installing the drivers seat back in I took the car for a test drive. I’m able to report that the clutch feels lighter and operates higher up. My opinion is if the pedal operates too low to the floor you lose the correct mechanical advantage of the cable to the pedal lever.
I have a question - has anyone been able to lubricate through gearbox bell housing inspection hole the thrust bearing forks, lower shaft bearing and the pressure flat fingers?
Martin (New Zealand)
1997 Saab 900S Talladega
84,000 Kms
posted by 203.96.111...
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