Clutch - Revised Slave Cylinder & Tools Available

CATEGORY
Transmission

SECTION
4

PAGE
13

ISSUE
06/93-0348

CODE
411

Subject:
New Method of Slave Cylinder
Removal/Fitting

Application:
99 and 900 Models





A new type of clutch slave cylinder has been introduced as a replacement part only. The new design incorporates a spring loaded bellows which protects the bearing from dirt. Also, the bearing is now in contact with the pressure plate diaphragm spring thus reducing noise level.

Cars Affected:

All 99, 90 and 900 Models

Parts:

Slave Cylinder P/N 87 29 840
Release Bearing P/N 87 21 995

A new set of tools is required for removing and refitting the new slave cylinders.

Removal/Fitting Tool Set P/N 87 92 186





This set (Figure 2) consists of:

^ Lever

^ Ring, Release Bearing P/N 87 92 038

^ Holder, Release Bearing P/N 87 92 020

NOTE
These tools have been designated as required specials tools and will be distributed to your dealership automatically during June 1993. Your monthly Saab parts statement will be billed after delivery.

Action:

A. To Remove

The slave cylinder of earlier design, see Service Manual 4:1.

The slave cylinder of new design, follow the instructions in Service Manual 4:1 (page 411-1) up to the point where the left-hand radiator fan (on cars with AC) and clutch cover have been removed, then proceed as follows.





1. Install tool 87 92 038 around the slave cylinder with the widest side of the tool facing the diaphragm spring, Figure 3.





2. Use tool 87 92 038 and the lever to press the diaphragm spring in. Install spacer 87 91 618 to hold the diaphragm spring in this position (on M84 and earlier cars use spacer 83 90 023, which is of smaller diameter), Figure 4.





3. Use two screwdrivers to press back the slave cylinder's rubber bellows and spring, Figure 5.

NOTE
Press the screwdrivers against the contact surface of the release bearing.





4. Hold the rubber bellows and spring in this position with one of the screwdrivers and install tool 87 92 020 over the bellows and spring, Figure 6. Take care not to damage the rubber bellows.





5. Remove the locking clamp, sealing ring and cover in front of the input shaft in the primary gear casing, Figure 7.

6. Unscrew the disc shaft's plastic propeller.





7. Install an M8 screw into the end of the input shaft and use the handle end of the lever tool to pry out the shaft. Leave the input shaft in the primary gear casing and remove the screw from the end of the shaft, Figure 8.





8. Press tool 87 92 020 with rubber bellows and spring against the pressure plate (rearwards on the car). This is to provide easier access to the socket head screws retaining the slave cylinder. Then rotate the tool as the three socket head screws are loosened and removed, Figure 9.

NOTE
Take care not to damage the slave cylinder's rubber bellows during this work.





9. Remove the pressure plate screws and lift out the clutch together with the slave cylinder, Figure 10.

B. To Fit

Before refitting the clutch, inspect the input shaft seal in the primary gear casing and the support bearing in the flywheel.

NOTE
When replacing the slave cylinder, tool 87 92 020 should be mounted over the bellows and spring.

NOTE
Coat the disc shaft splines sparingly with molybdenum disulfide paste such as Molycote Rapid G.





1. Install the slave cylinder together with the clutch, Figure 11.





2. Insert the input shaft so that it engages with the disc splines and flywheel bearing. Tap the input shaft until it is locked in place by the snap ring in the primary shaft pinion, Figure 12.





3. Install the six pressure plate bolts securing the pressure plate to the flywheel and torque to 23-28 N-m (17-21 ft.lbs.) Figure 13.





4. Apply loc-tite to the slave cylinder retaining bolts. Rotate tool 87 92 020 as the bolts are installed. (Slide the tool against the pressure plate to facilitate insertion of the socket cap screws), Figure 14.

5. Screw the plastic propeller into the end of the input shaft.





6. Install the sealing ring, cover and locking clamp in front of the input shaft, Figure 15.





7. Remove tool 87 92 020, Figure 16.





8. Press back the diaphragm spring using the lever and ring 87 92 038. Remove spacer 83 90 023 or 87 91 618, the lever and ring 87 92 038, Figure 17.

9. The system must be bled after replacement of the slave cylinder, see Service Manual 4:1 (page 412-9).

10. Install the remaining components in reverse order, see Service Manual 4:1.