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Yes, I now have the original PP, new stock Aero clutch, SS braided line, new slave, and new MC. It all works great, at least for now. Pedal pressure on the racing PP was much higher than stock, and now for some reason the pedal pressure is even lower than it was before the operation.
Quasi has a '94 Aero almost identical to mine except sans the ECU upgrade, and when I drove it I remarked how easy the pedal operation was. Now mine is the same. Could I have had an obstruction somewhere in the hydraulic line or sticking slave? The old rubber hose was not clogged, so what causes the pedal to suddenly require much less energy to activate when replacing these parts? Only the braided line is non-stock.
My advise to you is to avoid the racing PP altogether. Some have it working, but the two I have touched base with report that it engages very low on the stroke. Like I told Quasi, could my grouping of parts have been a bad combo due to production tolerances, all varying toward the wrong side of the range to produce this problem? Why then do their clutches operate well and mine didn't. This is still the nagging question.
Brad (George's of KC), an expert on Saab performance, wisely reminded me that any time you raise the level on performance you'll likely need to compensate elsewhere. In my case I knew I needed a 3" exhaust, but never considered the possibility that the clutch was not up to the task or the extra boost caused detonation that was not compatible with the 93-octane gas available here. In summer performance is down, so the solution is either water-injection or a larger intercooler, both adding more expense and hassle. I have a WI system here now that I bought from Brad, but I'm sending it back today. I don't feel the clutch in this car can handle any more performance, so I'll happily settle with the performance level I have now.
If this combo works without clutch slippage, I'll simply endure the lower performance in summer, as it still performs better than stock even on its worst day. If the clutch starts slipping again I won't hesitate to replace the ECU with the stock Aero unit and just fall back to square one.
When boost remains below about 20 psi the clutch did not slip. The stock Aero ECU allows stable boost to about 15 psi, spiking to 17 at the most. Now I'm getting 20 and 17 in this warm weather (85° highs here already in Baton Rouge).
One thing I never mentioned before is that the day I first noticed the clutch slippage was the day I washed the engine out with gunk. I liberally spray Gunk on the engine, except around electrical components, and I know that the tranny got a heavy dose. Later rinsing assuredly got some of the solution into the tranny case, so could that have impregnated the clutch disk material and caused the slippage from that point on? I don't know, but I do know that I won't be spraying Gunk anywhere near the tranny hole in the future.
posted by 68.11.251...
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