Removed the console and as you described the bushing was broken and the ball was out of the hole in the cable end. I ordered the stainless steel one with the hopes that I can do the JB weld correctly. Thanks for the suggestions for the stainless alternative.

 

I figured you would.

I have a write-up of the process which I created based on his directions. I did so to create a writing sample, which is something technical writers do to have something to demonstrate their style of writing and how they go about explaining things in words and pictures.

I have a migraine but will upload it tomorrow.
Funny I never thought there might be a real use for the document. Even if you don't use it, would appreciate a courtesy review as to whether it is understandable, straightforward, factually correct, etc. If I for some reason forget which is extremely likely, please remind me and I'll upload it.


I don't think I can attach it in a PM. I'll have to post it where the whole world can find it. Maybe I'll just change the name of it

 

Here you go.

Please read through the whole thing before you start so that you understand the process as you do not have time to think about it once you mix the JB weld.

 

VERY well written bulletin. I ordered this part and am awaiting it’s arrival. Wish my next phase was as easy! Test drove again today and in third gear applied full throttle and watched the rpm rise faster than car speed so I am convinced it is time for a new clutch. Per your previous post I checked the hydraulic part of the equation and the fluid level is full and the pedal feels fine and no leaks. The clutch does not begin to engage until pedal is very high towards top of play. The big question is can I replace the flywheel, friction disc, pressure plate, and throw out bearing without removing the engine?

 

It can be done.
I don't remember how I came across the article/post or where meaning on which forum, but apparently you can separate the two just far enough to be able to put necessary tools in the gap to remove the fasteners and other parts. I just got a job application rejection email at 3:30 in the morning. So now that I'm awake and pissed off I will try and find it for you.

 

That was easy

https://www.cristhomas.com/cars/Clutch/ClutchHowTo.html

At your own risk. Be safe.

 

Thanks for the link. Hope your migraines are not too frequent. I also have experienced these and they are no fun. One of the Triptan family of meds has helped me in the past. I will be also changing the flywheel so it appears that his method allows enough room for that. Appreciate the link for these steps because I was afraid the engine would have to be removed. I’ll keep you posted on my progress.

 

Great write up, derf. Easily understood in laymans terms and the photos were outstanding. Maybe you could be a technical service writer for repair manuals? Anyway, I've never heard of Teflon powder. Where in the world do you get that? One job rejection doesn't mean squat. You just keep going after the ones you're interested in and the right one will come along at the right time.

 

Thanks for the feedback. It's not a real TSB -- just written up to look like one.

Take a piece of Teflon and pulverize it.

 

There is another method of clutch replacement in the car where you separate the engine from the tranny by lake 9 inches, then play rotate-the-engine to access all the bolts/etc. Crazy tight working conditions but apparently can be done.

Honestly, you may just want to pull the engine and leave the tranny in place, or pull the engine and tranny as one and then separate and work on it. (Most popular and documented method.

Some folks remove the subframe and drop them out the bottom. The issue here is the fastening bolts on the frame are welded on, and if the weld breaks it can become a mess to reattach.
Others take them out the top. The clearance is a few inches so alot of the pulleys need to come off.

Richpin06a on youtube has about 75 saturn s series videos including pulling just the engine.
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Another important link -- this guy was a Saturn Tech --
https://www.saturnfans.com/forums/sh...ad.php?t=23753