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Discussion Starter #1
Dear All,

Hopefully a useful post to help others avoid some misfortune that I ran into the other day. My Saab 1.9 diesel, 1.9 8V was driving fine when suddenley, the clutch would not rebound when pressed - it stayed flat against the floor. Mangeed to limp home by putting a cargo strap around the pedal and pulled it back upwards after each gear change. The clue here is that there had been for some time on oily liquid under the battery tray. This looked "old" and I thought that it was some oil overspil from a past change - events showed otherwise....

Once I got the car back, I took the battery out and the box that it sits in. Removed also the turbo air pipe to give clear access to the area in question. Turns out that the hydraulic clutch has rigid plumbing around the engine bay, with a short section of rubber flex pipe between the bulkhead under the battery tray and the clutch bellhousing. This rubber pipe had been chaffing on a cable conduit for some time evidently, as it had gone through the outer coating, the innter reinforcement and the final, inner pipe, causing a leak. The fluid drained from the master cylinder, causing clutch failure. The strange thing was/is that the brake reservoir, from which the clutch draws its fluid, did not drain down - there was only a small drop in fluid level.

I have manged to get hold of another pipe from Neo Bros (£35) It could be possible to repair the damaged pipe too - I will make a trip to Pirtek to see what the specialists say. So, anyone out there with the same model, take the time to remove your battery and check your clutch flex pipe - you might be glad that you did.
 

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I also have a 05(55) 9-3 1.9TiD 120 and the EXACT same thing has happened to me today!
My brother alerted me to the friction on the pipe the other week and the clutch went to the floor on the way to work today, only for me to find fluid leaking from the hose. As you commented, the actual amount of fluid lost was/is minimal.

Would you care to provide a link to the correct replacement hose or a part/reference number please, as I am struggling to find it!

Thanks.
 

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I've managed to get the part number for the 'clutch connection pipe' as it seems to referred to.
SAAB number 55571778.

The SAAB dealer in Derby have them in stock but they are £68.32 inc vat! A lot of money for a tube!

Found some breakers who will post them for around £45 all in but even this seems a lot of a used pipe which may have already worn out somewhat.

Don't suppose anybody knows if there is a Vauxhall equivalent part number? Or if anybody knows of a cheap source?
 

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Discussion Starter #4
Thanks for your post - obviously mine was not a one off. I got a good secondhand pipe from Neo Bros for £35. It arrived today and appears to be in good nick. I thought about the possibility of a Vauxhall and will have a look in the scrappers when I next get chance. I am surprised that you found a dealer with one in stock - my local Saab dealer seems to have shut up shop to spares. I will call in my local Pirtek and see if the original hose is repairable. They are hydraulic hose specialists and may be able to put the Saab ends on a new length of pipe. I am encasing my replacement hose in some of that corrugated cable housing to give it more protection.
 
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