Going to change the clutch - what else should I do?

[jaherne]

Hi,
I'm hoping some people may be able to offer me the benefit of wisdom and experience and give me a few pointers. I'm going to undertake a clutch change on my 1985 2.5 lux with the aid of a mechanic friend of mine in the near future. I've done some research and I'm aware that this is one of the bigger jobs to do on these cars and I have a couple of questions that I'm hoping people could help with:
- Is there a single good comprehensive guide to doing this job (I've got a Haynes manual but don't intend to rely solely on it!)
- Whilst we're at it and the gearbox etc is out of the way for a while, what else should I think about replacing or checking? The car's got 130k on it and no record of a clutch change (which I would take to mean it has never been done as the service history I got with the car is very very comprehensive).
- I've got the clutch kit (a Sachs one that I picked up) but, depending on what else I should be changing, I'd appreciate any advice on the best source for good value parts.

Sorry for the long post - in all likelihood this job will get done over the Christmas break so I thought I'd post something now and see what info I get between now and when I do it. Many thanks in advance for any advice, I assure you all I really appreciate it and genuinely value any tips people can give me.

 

[Veerzigzag]

I had a recent clutch change at 155k miles on my 1989 2.7, for a Sachs unit; I think this was the first time the clutch had been changed. I had a new slave cylinder fitted at the same time; the old one looked OK, but silly not to do that while you are messing about in there. Something to watch out for: the garage managed to damage the rpm and tdc sensors; shortly after the job was complete, it started running rough then packed up all together. 2 x new sensors later, it was running much better than ever before particularly at low revs - I guess the old sensors really needed changing anyway! The Sachs clutch kit really works well. The clutch change job was 10 hours labour but I think it took them a bit longer.

 

[robdimond]

I've heard that the haynes manual is not that great although I think that's because it's based on the early car. You don't say if yours is a square dash or not...?

There are lots of write ups online, including Clarks garage and a lot of photos on the US site 944online.

You almost certainly want to do:

- Rear main seal
- Pilot bearing
- Clutch release fork bearings

May also want to:

- Rebuild the torque tube (replace bearings)
- Change the transmission oil
- Change the transmission drive shaft seals
- Inspect and repack the CV joints, also change the boots if they are split
- Change the rear brake/fuel lines while the transaxle is off, if they are original and rusty
- Replace the gearbox mounts
- Get the flywheel machined

 

[zcacogp]

James,

Clutch is pretty easy, just a long, long job. Only tricky bit is jiggling the clutch release lever in and out.

Read my comments here:

http://www.porscheclubgbforum.com/tm.asp?m=435928&mpage=1&key=clutch%2Cbearing%2Cseal񪛘



Oli.

 

[Veerzigzag]

Comment to "robdimond" - that is a seriously comprehensive list! If you look after cars so thoroughly , please let me know when you are next selling one..

 

[robdimond]

Hmm... yes I am a bit of a perfectionist which unfortunately means even the simple jobs spiral out of control into a whole list of while you're in there jobs. I think a lot of people on here are similarly minded though and I'm sure there is someone out there who would add a couple of extras onto my list [].

Also have a high mileage car which was a well-documented cheap ebay purchase and basket case for the previous owner!

I've been planning a front-end reseal and water pump replacement for almost a year now. Currently rebuilding a 2nd hand cylinder head and still waiting for good enough weather.

I can't see myself ever selling this car after the time I've put into it... although I have an itch for a 928 GT.

 

[Hilux]

although I have an itch for a 928 GT

...............if you think running a 944 is expensive []...........[]

 

[Veerzigzag]

"Project creep" is easy on an "old" Porsche (my latest one being a planned replacement of handbrake shoes turning into a complete rear brakes overhaul and fitting an EBC set), but you have the knowledge that it works because you made it work. Porsches are properly made and reward studious attention - it's why we like them so much.. Back to the clutch replacement - the brake lines and petrol lines advice seems very valid to me - it's a nightmare job unless stuff around the back end has been removed for other reasons.

 

[bighead]

ORIGINAL: Hilux

although I have an itch for a 928 GT

...............if you think running a 944 is expensive []...........[]

When one has an itch that needs to be scratch.....money is no object [], I also have the same itch for a 928 GT but having just spend £3k+ on the "S" since I bought it ....dont think the other half will be please if i go and swop it for a 928 !!

 

[Veerzigzag]

Life not being a rehearsal, you should have a look at this Darth Vader style 928 GTS: http://www.carandclassic.co.uk/car/C328664

 

[robdimond]

Life not being a rehearsal, you should have a look at this Darth Vader style 928 GTS

Looks lovely but if I bought that now my other half would see to it that I end up living in it, with all my worldly belongings in the boot!

 

[bighead]

yeah seen that advertise for awhile now ..dont think it will sell for £15k though , £10k maybe .

there a white S4 on ebay starting bid £4k i think , it in very good condition , but not one bid at all , now is not the time to buy a 24 years+ V8 Petrol gussler !!
If I've not have so many toys I might go and view it as it just 6 mile from me.

 

[Ewan]

I had JMG replace my clutch last week. "while we were there" we ended up with a new flywheel, spigot bearing, forks, rear main oil seal and a bill, at a guess, of maybe £1500 plus vat.

I also decided to have their shortest throw race shift kit fitted at the same time. This is about £250 plus vat from memory. Takes away all that "slop". Money well spent.

 

[Veerzigzag]

I also decided to have their shortest throw race shift kit fitted at the same time. This is about £250 plus vat from memory. Takes away all that "slop". Money well spent.

Is the kit installable without the transmission disconnected etc?

 

[944 man]

Answers: Clark's Garage and rear seal.