Clutch

Dismantling for changing the clutch on the 900I 8 with air conditioning
The work should be carried out as described for the 900i 16, except that the left-hand radiator fan must be removed to enable the clutch shaft to be withdrawn.


Dismantling for changing the clutch on the 900I 16

1. Remove the bonnet. Get an assistant to help on the other side of the car.






2. Remove the rubber bellows from the air cleaner and remove the throttle housing, and place them to one side. The wiring need not be disconnected. Push a piece of cloth into the throttle housing opening to keep out dirt.






3. Remove any plastic straps and remove the flywheel housing cover bolts. Remove the bracket for the battery positive cable at the top of the primary chaincase, and tilt out the left-hand side of the flywheel housing cover first.






Lift out the flywheel housing cover.






4. Get an assistant to press down the clutch pedal. Fit spacer 83 90 023. Use tool 83 94 033 to press in the diaphragm spring.






5. Remove the clip and cover in front of the clutch shaft.
6. Remove the plastic propeller.






7. Screw an 8 mm bolt into the end of the clutch shaft and use tool 83 94 033 to withdraw the shaft. After withdrawing it, leave the shaft where it is.






8. Remove the three slave cylinder bolts.

CAUTION: Take care not to damage the slave cylinder sleeve during removal.






9. Remove the pressure plate bolts and move the pressure plate to one side, together with the slave cylinder.

TO FIT

Before re-assembling the clutch, check the condition of the clutch shaft seal located in the primary drive chaincase, and the condition of the support bearing in the flywheel.

NOTE: Lubricate the clutch shaft splines sparingly with molybdenum disulphide paste or Saab Special chassis grease.






The hardened side of the release bearing must face towards the clutch.






1. Fit the pressure plate unit, clutch plate and slave cylinder with release bearing together into the flywheel housing.






Fit two of the pressure plate bolts but do not tighten them.
Push the clutch shaft into engagement with the clutch plate splines and into the support bearing in the flywheel.






2. Finally, tap in the clutch shaft so that it is locked by the snap ring in the primary drive sprocket.






3. Apply thread sealing compound to the bolts. Bolt the slave cylinder to the primary chaincase.






4. Fit the plastic propeller to the end of the clutch shaft.
5. Fit the seal, cover and clip in front of the clutch shaft.






6. Bolt the pressure plate unit to the flywheel.

CAUTION: Don't depress the clutch pedal further than necessary to remove the spacer. The lip seal may otherwise be pressed out too far, and hydraulic fluid will then leak out and the seal will be damaged.

7. Get an assistant to press down the clutch pedal and remove spacer ring 83 90 023.






8. When the clutch has been fitted, push the plastic sleeve against the release bearing.
9. Fit the flywheel housing cover.
10. Refit the clips for the battery positive cable.
11. Reconnect the bellows to the air cleaner and refit the throttle housing.






12. If the car has an air conditioner, fit the left-hand radiator fan.
13. Fit the bonnet and connect the hose to the windscreen washers.