Clutch "squeeking"?

adg, I think you need to be very persistant with the dealer, and have them make it right, regardless if you got the "deal-of the-century" or not.

Another problem you might have is, the dealer will not have any others new 2004's sitting on his lot to compare, so you need a different strategy before you go in.

[adg]

From the sound of things, I take it that this sound is not normal.

When the service guy tells me that the clutch on all Boxsters make this sound he appears to be brushing me off.

Am I correct?? Do any of you hear a "squeak" when you depress the clutch?

Again, it is not terribly bothersome, and it does not appear to be coming from anything other than the pedal inside the car.

Thanks

[deliriousga]

It's definitely not normal. I don't experience it at all. Also, if it were normal, there would not be a Technical Service Bulletin out telling how to fix it by replacing the spring mechanism.

The TSB may not cover your MY, but it does show that Porsche considered it a problem and told their mechanics how to fix it showing it is not a normal situation. Here's the TSB info:

TSB #1A/00 Date: 010601 Clutch Pedal - Various Types of Noises

Squeaking noise

Cause:
The clutch pedal power assist spring touches the spring casing.

Repair:
Replace the clutch spring.

Note: There is a new contoured version clutch spring that can only be installed in MY'00 and later vehicles. The boost spring for MY' 98 and MY' 99 vehicles has not changed. The new contoured version clutch spring was installed in production as of the October 6, 1999 from the following VIN numbers

[tommy986]

Do you have a link to the full text of the TSB?

I want to see if my 2000 S has the new spring. It's a little squeeky and very stiff.

thanks

Tommy

[deliriousga]

Here's the full text:


Clutch Pedal - Various Types of Noises

Boxster

1a/00 3005


6-1-01

Binder - 3, Manual Transmission

This bulletin replaces bulletin Group 3, # 1/00 dated 9/8/00.

Clutch Pedal Noises (MY '98 - On)

Vehicle Type:
Boxster / Boxster S

Model Year:
As of 1998 (W)

Concern:
Noises during actuation of the clutch pedal

Information:

When operating the clutch pedal, various types of noises may occur. When diagnosing the noise, leave the drivers door open. This will allow you to detect any noises that may be external in nature.

Important Note: The previous bulletin should not have included MY' 97 Boxsters.
Please refer to Boxster Technical Manual; Group 3 page 30-15 for proper boost spring allocation.

Work Procedure:
Scratching or scraping noise

Cause:





The clutch pedal reinforcing rib rubs on the bracket (see arrow in Figure 1). This noise is only slightly audible.

Repair:
Remove the clutch pedal and rework the reinforcing rib with a file.

Note: A clutch pedal with modified reinforcing ribs has been introduced into production as of July 26, 1999 with the following VIN number 98 0YU 62 0216.

Squeaking noise

Cause:
The clutch pedal power assist spring touches the spring casing.

Repair:
Replace the clutch spring.





Note: There is a new contoured version clutch spring (see arrow in figure 2) that can only be installed in MY'00 and later vehicles. The boost spring for MY' 98 and MY' 99 vehicles has not changed. The new contoured version clutch spring was installed in production as of the October 6, 1999 from the following VIN numbers:

98 8YS 62 0335 (Boxster)
98 1YS 66 0138 (Boxster S)
98 9YU 62 2504 (Boxster)
98 2YU 66 0346 (Boxster S)

Work Procedure
Replacing the Boost Spring in MY' 00 and later vehicles:

Part Number Description

996 423 081 12 Boxster S New contoured version spring
996 423 081 11 Old version spring no longer available
996 423 881 06 Boxster - New contoured version spring
996 423 881 05 Boxster - Old version spring, no longer available

Replacing the Boost Spring in MY' 98, MY' 99 vehicles:

Part Number Description

986 423 081 11 Boxster - New (same version-not contoured) clutch spring

986 423 081 08 Boxster - Old version, no longer available

In addition to the new clutch spring, MY'98 and MY'99 vehicles must use a new clutch pedal and bolt.

Part Number Description

996 423 139 10 New Clutch pedal
996 423 315 06 Bolt

Clicking noise

To repair the clicking noise, follow steps 1 to 3 in sequence.

Step 1:

Cause:
Insufficient lubrication of the ball socket in the clutch master cylinder

Repair:





Spray the ball socket in the master cylinder with spray lubricant (figure 3). If this does not eliminate the noise, continue with step 2.

Part Number Description

000 043 204 40 New/Spray lubricant

Note: As from October 1, 1999 the master cylinder has been modified in the area of the ball socket.

Work Procedure

Step 2:

Cause:
The spring of the boost spring touches the spring casing (see also squeaking).

Repair:

Install a new contoured version clutch assist spring in MY'00 and later vehicles. Replace the boost spring in MY'98 and MY'99 vehicles. If this does not eliminate the noise, continue with step 3.

Step 3:

Cause:

A shoulder may be worn into the clutch pedal reinforcing rib from rubbing on the bracket (see scratching / scraping)

Repair:

Replace the clutch pedal with a new version with a modified reinforcing rib.

Part Number Description

996 423 139 10 New version pedal
996 423 139 09 Old version pedal, no longer available
996 423 315 06 Bolt - Use when installing the clutch pedal in MY'98 and MY'99 vehicles.

Literature:

Boxster Technical Manual, Group 3, Manual transmission:

Repair:

30 - Boost spring: Allocation and grease specification 30 05 19 - "Removing and installing the clutch pedal".

Technical Information: 1/99 - "Boost spring and clutch pedal".

[PA986S]

My 01 Box squeaks every time I hit the clutch and it drives me nuts.

[adg]

Well...I took it back to the dealer today and met with the Serivce Manager.

He was very understanding and said that it definately was not normal and made an appointment to bring it in.

Only wish I didn't have to go back, the dealer is not that close to my home. Will post what happens after the serivce.