Clutch and gearbox?

[gazzy]

Hi all,
I've recently bought a 91 S2, I'm not new to Porsche's but new to 944's and really like the car, but, have a relatively small issue. When releasing the clutch there is sometimes a quite loud clunk, particularly when engaging reverse which can be felt through the car and 1st to 2nd and 2nd to 3rd gear changes, the gears trail. Just wondered if there's anything I should look at, apart from these issues I really like the car, any advice appreciated.

 

[Monkeythree]

Engine and gearbox mounts would be my first port of call.

 

[white944]

Drive doughnut in the clutch.

 

[gazzy]

Thanks for the swift replies, I'll go for the easy one first, what should I be looking for on the mounts? If they seem ok how difficult is it to do the clutch? I'm pretty good with the spanners, there's not too much that I won't tackle on my cars but it is all done on my driveway under axle stands,

thanks again,

 

[Waylander]

S2 clutch, gearbox and torque tube out, indies normally quote 6-8 hours labour if think

 

[robwright]

I don't think the S2 had a donut and I would bargain m8re than 6-8 hoirs for that iob. More like up to 20 or 24 for a turbo. Chech fluid etc first. you can check clutch wear from the inspection wimdow on the bell housing. As always there is a guide at www.clarks-garage.com

 

[zcacogp]

S2 most certainly did have a doughnut (UK spelling please chaps!) and my guess is also that it's hopajooped.

Times for N/A and Turbos are quite different as I understand that there is a quantity of turbo pipework to remove. I changed the clutch on my S2 about 5 years ago and it took me and a friend a weekend with a garage with a pit and air tools. OK, we went intentionally slowly and could do it a lot quicker if we were doing it again but it's a long, long job. The good news is that no part of it is hard, it's just that there is a lot to do.


Oli.

 

[Monkeythree]

Thanks for the swift replies, I'll go for the easy one first, what should I be looking for on the mounts? If they seem ok how difficult is it to do the clutch? I'm pretty good with the spanners, there's not too much that I won't tackle on my cars but it is all done on my driveway under axle stands,

thanks again,

Get it safely up on at least 4 axle stands then give the engine and gear box a good shoogle (fine Scottish term which means grip firmly and shake vigourously). You will feel/hear if there is undue play in the mounts. If they all seem good then move on to the clutch duffnut.

 

[pauljmcnulty]

S2 most certainly did have a doughnut (UK spelling please chaps!) and my guess is also that it's hopajooped.

Oli.

Thanks, Oli. I was going to have to put people on a warning about that if you hadn't stepped in! []

 

[tobybanks]

If you get under the back end,remove the large inspection port on the transaxle you will see the torque tube.With the gears in neutral if you can turn the torque tube by hand then the attached picture will be your problem

.Guess what I'm doing at the moment!!

Toby

 

[tobybanks]

Second attempt at picture!!

 

[gazzy]

Thanks for all the replies gentlemen, plenty to look at there then. As and when I get to look at it I'll let you know what I find.

 

[zcacogp]

S2 most certainly did have a doughnut (UK spelling please chaps!) and my guess is also that it's hopajooped.

Thanks, Oli. I was going to have to put people on a warning about that if you hadn't stepped in! []

Pleasure to be of service Mr McNulters sir! >DoffsCap< >TugsForelock<

We need to maintain standards around these parts and that won't be achieved with yankee words like 'Donut', now will it? []


Oli.

 

[Waylander]

He he

dam spell checkers on iPads don't help

specialize, and so on

 

[Elliot]

changed clutch in a 1988 today with fractured rubber - always quote 10 hours to allow for unknowns - your symptoms are 99% fractured rubber clutch - if you need any advice feel free to call me on 07514 944964

 

[robwright]

If you have nice post lift yes. You can almost double that if you are doing it on your back on your drive Elliot.

 

[Mikebarry202]

I'm literally half way through a clutch change (well, fully stripped and ready to reassemble, so in theory it's half way but in reality I reckon 2/3 of time to strip and 1/3 of time to assemble). Doing it in my rented garage with no power/light, on axle stands, 2.5T trolley jack for the gearbox, and with a knackered back!
Nightmare bolts, in particular the rear silencer heat shield bolts, the lock wired bolt on the gear selector rod that snapped as I showed it a socket (!!), the hall sensor bolts and one of nine clutch bolts that just chewed itself to death!
still, happy as Larry to have removed them all, now to reassemble. Oh, wrong bolts for the clutch sent through so that'll be another delay.
Not timed exactly but I reckon on 30 hours so far.... with all that said its not technically difficult ??

 

[pauljmcnulty]

I'll still refer you back to the well-documented clutch change Ken Tolfree did on Andy Mais' S2.

He charged 5 hours, doing it on the road side, at £40 per hour.

Sonetimes it's worth letting the experts tackle the bigger jobs. Elliot's estimated 10 hours worst-case seems so much more appealing than 20 hours on your back, in November, learning how to do it yourself.....

 

[zcacogp]

You can sometimes see bits of the crumbled rubber doughnut in the inspection hole at the side of the bellhousing, which is a dead giveaway. Although I'd be pretty confident that is your problem even if you can't see them.

Estimating times for a job has far too many variables to be accurate. How quickly does the person work? What tools does he have? Has he done the job before? Does he have all the parts necessary? While one chap could do a clutch in 8 hours it may take another guy 16, or 20. Best advice is to read the procedure in detail on Clarke Garage beforehand (http://www.clarks-garage.com/shop-manual/clutch-01.htm) and think for yourself about the steps. It's worth noting the introductory paragraph on that page; "Replacing the clutch on a 944 can be one of the most intimidating jobs a home mechanic can undertake."

Oli.

 

[gazzy]

Gentlemen, once again thanks for all the replies, as I said in my initial post, I'm not new to Porches but new to 944's. My experiences in the past, when asking questions, have always been one or two stalwarts trying to help, this response has been quite eye opening. I have noticed that the other sub forums I go on have been quite dead recently, the 944 section always seems to have something going on, is this something to do with the type of people that own 944's? A more genuine enthusiast perhaps? Anyway, thanks again, as soon as I get to have a look I'll let you know what I find. In the meantime should any of you wish to come and do the job for me, feel free, I will of course provide tea and moral support from my armchair and you'll be guaranteed a place in heaven.