Saab 900 Clutch Repair

This is an edited version of a 4-hour livestream as I replaced a badly worn clutch master cylinder in a 1994 SAAB 900 Commemorative Edition. A long day in the shop is squeezed down to just the good stuff. You'll learn how to bleed the system using a vacuum device, see the clutch slave cylinder in action and learn how a few special tools make the whole process easier.

[@pbutter237]

Your determination to do this project really blows me away! Your best day will be when you finally get to drive it. I know now what issues to look for in my antique 1989 sedan.

[@LeeKelso]

Thanks. I've learned that patience and anger management are critical in working on old cars. It helps that I have a dedicated workspace and other transportation so I can simply walk away and open a beer when frustration builds.

[@bobruder6392]

You may have felt my pain as the clutch on my 94 900 turbo vert let go at a busy intersection last night. I knew something was wrong but thought I could nurse the car to my Saab mechanic. Some days you're the statue, others the pigeon.

[@LeeKelso]

A sudden failure hints at hydraulic issue in the master, slave or line. Was it slipping prior to failure? My clutch engagement point was near the floor prior to this project and as you saw, the master was to blame.

[@bobruder6392]

​@@LeeKelso Good morning Lee. What a nice and unexpected surprise hearing from you. My Saab guy in Lancaster County and you are in the same page! The line failed as well as the shift coupler. My fav car is now with my fav mechanic! I'll keep you informed. I love your videos but lack your level of skill as well as the equipment to do you work. Thank you.

[@bobruder6392]

My Saab is back in service but until it is warm, shifting into 3rd gear may cause a grinding of gears. Of course I'm disappointed at my own stupidity for not having the car towed at the first sign of clutch line failure.

[@bobruder6392]

Lee, just very curious what caused the issues with third gear? Thank you.

[@jerdobi]

I saw you replaced the steering rack in the "about". Bet that was a bear. Be cool to see video on how to refresh the power steering fluid. I need to do that soon.

[@LeeKelso]

It was actually pretty simple - with the engine out of the car. Wouldn't be much fun otherwise. There are two bolts that hold it in place and once they're out it was easy to lift away. I put the new rack from the wrecked '89 into the '94 as part of this project. To drain the power steering fluid the Bentley manual recommends you remove the return line at the reservoir and direct it to a catch bottle, then start the engine and let the pump drain the system. You could also get under the car and remove the hose at the rack and let gravity drain it but be sure to turn the steering wheel fully in both directions to force fluid out of the rack itself.

[@agapioskalokerinos9467]

Nice video, I just replaced the master cylinder in my 94 900 CE, I've been unable to bleed the line. I have spent several hours working on it, I get no clutch pressure. I used a hand vacuum pump connected to the bleeder nipple but air keeps coming out, I'm starting to think I got a bad master cylinder, LUK brand.

[@LeeKelso]

That certainly sounds like a possibility. As you saw, that was the problem vexing me. The car has been on the road and running fine all summer since changing that master cylinder.

[@agapioskalokerinos9467]

@@LeeKelso I replaced it with new LUK master cyl but unable to bleed. Guess I'll keep trying with the hand pump.

[@kaisertrinityt.m.i.s1607]

hello lee kelso. i was looking far and wide but couldnt find any to clear my mind. they say the transmission is a weakspot in every saab 900, but do i really have to dread? i wanna build in a T5 trionic, so how much torque and force can the transmission resist? is there a way to make it stronger? so i can beat all the stupid BMW and AMG driver? also when i choose stage 1 for my trionic, do i have to change the turbo pressure kick? (can i still run it on 0,45 bar?) thanks for the answer, from me and my saab the incredible driving thunder. (sorry for the rhime, it was just kicking in ;) also, greetings from germany. guten tag und auf wiedersehen!

[@LeeKelso]

It is true they are a weak spot, but many guys run pretty steep boost without a problem. Jordan Pagano is producing several T5 components, including a stronger diff cover to help reinforce the tran case and resist cracking. Info here: www.modernclassicsaab.com/blog/articles/trionic-5-conversion-what-you-need

[@nytrogenify]

Problem is gearbox,too weak for 175 hp.Use only mineral gearbox oil.That want solve problem,just for advice.My 900 from 81' run on very first MCC ,it's being dirty inside but i fix this😉.Cheers and drive youre SAABs like strorm!!Great car's!!

[@RetrocarStyle]

Lee I forgot to ask you during this live stream....where did you source the new clutch line?

[@LeeKelso]

Sorry for the slow response. I think that came from AutoHouzAZ, but they're also offered be Eeuroparts.

[@RetrocarStyle]

@@LeeKelso Thanks!

[@theonewhoknows2817]

There are actually 2 clutch cylinders.

[@LeeKelso]

You're right. The slave cylinder is the one that delivers the result and I'm glad to see it's working - again.

[@theonewhoknows2817]

@@LeeKelso i replaced both on my 89 900t ragtop. Like all your vids