Transmission / clutch failure - 986 Forum - The Community for Porsche Boxster & Cayman Owners

MN 986 · 03-09-2010, 06:11 PM

Quote:

Originally Posted by yimmy149

Other things to consider:

At 60k your front engine mount is shot unless it's already been replaced. The clunking you hear could be your engine moving.

It's worth checking that your transmission linkage is still connected. Does the car feel like it's going into gear as you move the shifter?

+1 on checking the front engine mount. I have a 2002 986 with similar miles, and I just started noticing a very slight noise under these conditions. I have read many posts on a few different forums, and I am convinced it is the front engine mount.
It is worth checking since it is a lot cheaper than pulling the transmission.
Good luck!

Roosell · 03-10-2010, 01:03 PM

Thank you to each of you for the responses.

R~

Lil bastard · 03-10-2010, 05:30 PM

Not tranny or engine mount, at least not initially. It may have taken the engine mount with it.

What I think you have is failed clutch mechanicals - TO, Pilot bearing and/or pressure plate.

Could be shifter mechanism too, but I'm betting clutch.

Cheers!

Roosell · 04-09-2010, 12:18 PM

The verdict: Clutch assembly. The repair shop insists that the clutch in the car was the wrong clutch (possibly a disk and pressure plate from an S model?). The center of the clutch disk was larger than the transmission input shaft, and they were surprised the car ever moved. Fortunately the input shaft wasn’t damaged when the clutch plate finally lost its grip and started freewheeling. The pressure plate fasteners weren’t completely tightened / flush, and had struck something while rotating. They were bent, and had to be cut out.

The pressure plate diaphragm fingers didn’t match up with the throw out bearing properly. The bearing barely touched the fingers. The rub marks are visible at the very tips of the fingers, and it looks like eventually the throw out bearing would have been pushed inside the ring of fingers. For sure, the clutch peddle action is much lighter now! The flywheel was damaged, so I got to buy another one ($900!). This has been quite expensive. Thanks for the input, guys!