Changing the clutch

[chriscoates81]

Hi guys how easy is it to do and is it possible for me to diy it? I notice the kit seems to be around £250ish and porschtek say it will be 400 labour is that about right?

 

[chriscoates81]

Anybody?

 

[chriscoates81]

Bump.

 

[Richard_Hamilton]

Depends how handy you are. Book time is about 4 hours, so around £220-250 labour at an indy.

Here's a couple of extracts from the manual:

Remove transmission:

1. Remove underbody panels (middle and rear).

2. Remove cross member.

3. Support engine with special tool retaining device 9624/1 . To do so, remove the anti-roll bar mount and pivot anti-roll bar forwards.

4. Assemble special tool retaining device 9624/1 on the body with the anti-roll bar fastening screws and adjust pressure screw so that the pressure disc is aligned with the crankcase.
Note
Protect drive shafts against damage, e.g. with hose (30 mm diameter)

5. Remove drive shaft on transmission side.

6. Separate electrical connection from the back-up light switch.

7. Unclip the hydraulic line for the clutch slave cylinder at the side transmission case cover.

8. Unscrew clutch slave cylinder and suspend on side. Do not remove hydraulic line.
Note: The clutch pedal must not be pressed if the clutch slave cylinder has been removed. Danger of injury from the push rod which can be pressed out of the slave cylinder hydraulically. Affix a warning note in the vehicle!

9. Remove switch cable from the transmission and pull it off the transmission switch and selector lever.

10. Place transmission jack under the transmission and fasten fixing strap.

11. Remove gear support.

12. Remove transmission bracket.
Note: The transmission can be lowered by a maximum of 25 mm to improve accessibility.

13. Unscrew fastening screws (8) between engine and transmission.

14. Pull transmission to the front and lower it.

Remove cluch:

1. Remove manual transmission.

2. Fasten toothed segment (special tool 9538/1) on the crankcase half (cylinder bank 1 - 3) with hexagon-head bolt M12 x 50.

3. Detach thrust plate.
Note: In order to avoid deformation of the thrust plate housing, always loosen screws in several stages and in diametrically opposite sequence.

4. Remove thrust plate and drive plate.

If you would like a copy of the pages, drop me an email.

 

[chriscoates81]

ORIGINAL: Richard Hamilton

Depends how handy you are. Book time is about 4 hours, so around £220-250 labour at an indy.

Here's a couple of extracts from the manual:

Remove transmission:

1. Remove underbody panels (middle and rear).

2. Remove cross member.

3. Support engine with special tool retaining device 9624/1 . To do so, remove the anti-roll bar mount and pivot anti-roll bar forwards.

4. Assemble special tool retaining device 9624/1 on the body with the anti-roll bar fastening screws and adjust pressure screw so that the pressure disc is aligned with the crankcase.
Note
Protect drive shafts against damage, e.g. with hose (30 mm diameter)

5. Remove drive shaft on transmission side.

6. Separate electrical connection from the back-up light switch.

7. Unclip the hydraulic line for the clutch slave cylinder at the side transmission case cover.

8. Unscrew clutch slave cylinder and suspend on side. Do not remove hydraulic line.
Note: The clutch pedal must not be pressed if the clutch slave cylinder has been removed. Danger of injury from the push rod which can be pressed out of the slave cylinder hydraulically. Affix a warning note in the vehicle!

9. Remove switch cable from the transmission and pull it off the transmission switch and selector lever.

10. Place transmission jack under the transmission and fasten fixing strap.

11. Remove gear support.

12. Remove transmission bracket.
Note: The transmission can be lowered by a maximum of 25 mm to improve accessibility.

13. Unscrew fastening screws (8) between engine and transmission.

14. Pull transmission to the front and lower it.

Remove cluch:

1. Remove manual transmission.

2. Fasten toothed segment (special tool 9538/1) on the crankcase half (cylinder bank 1 - 3) with hexagon-head bolt M12 x 50.

3. Detach thrust plate.
Note: In order to avoid deformation of the thrust plate housing, always loosen screws in several stages and in diametrically opposite sequence.

4. Remove thrust plate and drive plate.

If you would like a copy of the pages, drop me an email.

Thanks, hmm i might have to take it somewhere. Unless theres a place where i can get all these special tool.

 

[Richard_Hamilton]

9624/1 is to support the engine while you remove the transmission, as it is normally supported by the transmission mount at that end. 9538/1 is a toothed piece which locks up the flywheel, so you can undo the pressure plate bolts easily without the flywheel rotating. Depends if you are good at improvisation as to whether you need them or not.