What are possible reasons for a 1995 Saab 900 grinding in the front of the car when switching gears?

Answer 1

That year has a cable clutch linkage from your clutch pedal to the transmission, and it tends to wear and STRETCH, causing the clutch to not be fully disengaged even though your clutch pedal is pushed all the way down to the floor. It is a design flaw as there is no cable-length-adjustment. Saab came out with a TA that instructs mechanics to use TWO (instead of just one) spacer washers when replacing this cable, to help forestall how soon this happens. There is an aftermarket replacement cable that has an adjustment built in. I postponed replacing my cable for about 6 months by shimming where the cable attaches to the clutch arm: I cut a slot in a fender washer so I could slip it over the cable without taking the cable out. I bent the washer to match the curve of the clutch arm. I then inserted the washer between the clutch arm and the ball at the end of the cable, effectively shortening the cable by the thickness of the washer...but eventually you will need to replace the cable. If you use this fix and later feel it grinding the breaking of the cable is IMMINENT!