Quote:
Originally Posted by epapp
I didn't read some pages of the post, but what parts of the clutch assembly did you replace? Had same symptoms recently with hard to engage gears. Slowly turned to impossible to engage any gear unless motor was off. My pressure plate was broken (creaky) and the clutch fork was cracked (I assume less cracked/bent when selecting gears was still hard but possible, i.e. the stage you are at). Hopefully those were part of the replaced parts list?
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Before i dropped my transmission at the beginning of the project i had been researching this clutch problem. After replacing the hydraulics and bleeding the system several times with my power bleeder I expected to find your scenario: the clutch fork cracked and/or the pressure plate FUBAR.
Neither was the case. There was some wear but nothing glaring. I ordered all new parts from Pelican and went with the updated 987 lever and all the parts that go with it, plus pilot bearing, throw out bearing, and pressure plate.
The 987 parts are supposed to resolve a creaking sound that annoys some people. If i was a doctor who just spent $70k making a statement i maybe could relate. As an engineer just trying to have some fun with a 15 year old car, if i understand what makes a noise and know it is working properly and not going to get worse i could care less about such details.
That clutch fork, along with the one i took out are actually pretty beefy steel stampings. Had i not ever seen pics of a cracked one i would consider it unlikely. They probably did a poor job of deburring the opening which the shaft goes through, leaving a stress riser that would eventually crack.
I know, blasphemy to suggest that Porsche parts aren't all made by journeyman machinists in lab coats. I can assure you there are many off the shelf "supplied parts" in these cars.