Turbo clutch

[James0]

So I've got a week off, I still haven't found a silicon hose kit to ensure water tightness. However regular driving has high lighted just how ruined the throwout bearing has become. I can't live with the noise so have bitten the bullet on a full clutch kit fron Design 911.
So it's been a while, engine out or in via the arse? I can't decide which is the least ball ache.
I have a hoist but it's lost some of its newness, it'll lift an engine but that's about it.

 

[IanK]

I believe its start at the back and work forward - driveshafts > gearbox > exhaust > torque tube and you are there.

That's how my S2 was done anyway.

Ian

 

[PSH]

engine in, as Ian states, start from the back, it's a long job, allow a good weekend with all the right tools and a ramp, if on the drive allow longer, personally, I wouldn't even attempt it on a drive but others have. Be prepared for needing a rear main seal, spigot bearing and reference sensors if they full apart when removing, clutch fork bearings are worth doing at the same time. Be sure to get the latest clutch, the old ones had 6 small springs, the newer ones have 4 larger springs.

Pete

 

[Dan944t]

What ever you do ....don’t take the engine out just to do the clutch.

All you have to ve to do is drop the gearbox at the rear. Then undo the torque tube onto the bell housing bolts x4. You’ll have to drop the majority of the exhaust system obviously . Then pull the torque tube back and it will reveal the clutch mate and you just reverse the removal ????

atb
Daniel

 

[James0]

Yeah I did it some years ago when the paddle clutch disc from D9 wore out I dropped a machined down 911 clutch plate in as I didn't have the cash for a full kit.
The reference sensors on mine only really drive the dash.

The attractive part of pulling the engine is I can do the belts etc at the same time. It's not quite 5 years but not far off on the belts.

Thanks for the tip on the clutch PSH

 

[Diver944]

We did Tony F's Turbo using the guide on Clarks Garage http://www.clarks-garage.com/shop-manual/clutch-01.htm

Long winded but fairly straight forward up on a lift (as long as nothing is too seized)

 

[blade7]

I don't think the quoted workshop hours are a lot different between removing the engine and changing a turbo clutch. As you've pulled the engine before at least there won't be any surprises. PITA finding a problem underneath an old car, when it's 2 ft away from your face.

 

[Waylander]

2ft, blimey that’s miles away

 

[blade7]

Not when your breaker bar is 3ft...

 

[James0]

I guess I'll see next week.
It'll depend on the the following:-
1. If the engine hoist needs Viagra
2. If I can find my cobbled together transmission holder-upper.

3. If I can get one of my axle stands out from under the shelving unit which it is supporting currently, without being crushed to death by random Porsche parts.

 

[edh]

My top tip.... cover the bellhousing holes before you adjust the reference sensor bracket... dropping something in there at the final stage of a clutch job is a touch annoying [] (Ok so I might have personal experience of this one..)

Clutch fork bearings are a simple change, maybe also replace the shaft as they can get quite worn.

Also check the transmission mount & possibly fill with urethane if it's looking tired.

 

[IanK]

This was my parts list - 2 years ago so prices will have changed!

£406 Clutch Kit
£ 17 Spiggot Bearing (93110211100)
£ 52 Guide Tube/Sleeve 016141181 ( + Bolt N0901942)
£ 57 Clutch Fork Shaft 95111613300
£ 14 2 Bearings for shaft. 99920121300
£86 O2 Sensor 94460613502
£22 Exhaust header gasket x 2 94411113501
£99 Crankshaft speed sensor 94460611500/1
£12 Torque tube pinch bolts. X 2 93142124000

These were for an S2 so some of yours will be different.

Ian

 

[James0]

Well cheers for all the tips, gearbox is out and I've just spent an hour getting the front high enough/safe enough to work under. Looks like I might be doing a spot of plumbing too judging by the whiff of fuel at the back.

 

[blade7]

Where did you get the 968 pistons from?

 

[James0]

They were in the 968 engine.

Inlet off and I'm surprised it made any power. Air leaks everywhere.
The bolt that holds the dipstick tube to the manifold has to be th biggest pain for such a tiny thing.

 

[Waylander]

They were in the 968 engine.

Inlet off and I'm surprised it made any power. Air leaks everywhere.
The bolt that holds the dipstick tube to the manifold has to be th biggest pain for such a tiny thing.

now that is one fiddly little bolt, and what worse is its right in front of you.

there are a few jobs like that, the litttle plastic arm on the door handle for one, what a pain that is to get back on

 

[James0]

I remember now why I've been putting off dealing with the throwout bearing for so long!
Gaskets, belts and a new voltage regulator on order. Will hopefully arrive before I start reassembly of the front end.
Exhaust and crossover pipe bolts have been left to soak in penetrating fluid and beer is being consumed.

 

[Dan944t]

They were in the 968 engine.

Inlet off and I'm surprised it made any power. Air leaks everywhere.
The bolt that holds the dipstick tube to the manifold has to be th biggest pain for such a tiny thing.

now that is one fiddly little bolt, and what worse is its right in front of you.

there are a few jobs like that, the litttle plastic arm on the door handle for one, what a pain that is to get back on

I second that little barstard 10mm bolt! Still have to put mine on, there’s cable tie in mine at the minute Becuase I had to remove and install the poxy manifold about 4 times due to chasing boost leaks. So that’s just reminded Me ??

 

[Dan944t]

Exhaust and crossover pipe bolts have been left to soak in penetrating fluid and beer is being consumed.

[/quote]


This made me laugh ?? becuase when I rebuilt my whole engine along with everything else last year , I consumed a huge amount of beer too ?? I remember it was quite a nice feeling!

 

[James0]

My liver won't be happy, clutch slave cylinder has a leak. Beer break for parts shopping.