2002 Boxster S Clutch Replacement

[deliriousga]

Originally Posted by Mr. Boone

Thank You. If you do yours first let us know how it goes. I am pretty sure I can do it myself but don't know if I want to take the time and effort. I own a Porshe Official workshop manual for the car and it shows the need for a special support bracket that straddles the trunk and supports the engine while you have trans out. I am assuming it is actually necessary. God only knows how much the dealer wants for this special tool and I think it could be fabricated easily. My biggest concern is without the aid of a lift, how do you safely get the car high enough for the trans to roll out of the way from underneath it?? You have lift in your garage??? I don't......

I don't have a lift. I use 6 ton SUV stands to hold her up. They have huge bases so they won't tip and I can raise it up 24". I used them on the 928 clutch and it was no problem at all.

For the special tool, I believe that article talks about supporting the engine from underneath. I always have a floor jack underneath, even with the stands, pressing lightly on the oil pan just in case so I'll put it where it can hold the engine up safely and even with the tranny. It doesn't look too hard to do with the whole thing coming out.

I'll be replacing mine along with a lightweight flywheel with inserts since the dual-mass OEM flywheel on mine is causing vibration. I'll let you know how it feels compared to the original whenever I get it done. I'm sure I'll be replacing it before you have to. Ours is a daily driver, 60-80 miles/day so it probably won't be long.

[Porschekid]

My clutch feels like it catches a little on the high side (almost have to let it all the way out). Does this mean my clutch could be going or needs an adjustment, or is this normal? It still feels like it shifts and catches just fine...

[deliriousga]

The clutch automatically adjusts itself so you don't have to worry about it.

As far as wearing out, as the clutch disc wears/thins, the pedal has to travel further out before the disc catches the flywheel.

To help with how the clutch works, here's a great article with animated illustrations of what happens inside the clutch assembly http://auto.howstuffworks.com/clutch1.htm

There are a couple of differences in your clutch from the one that's in the illustration. When you get to the exploded view of the clutch assembly, the clutch disc (plate) in their illustration has the central shaft attached, but in reality it is separate from the clutch disc. The disc slides back and forth on the shaft when the clutch is engaged so it can't be attached. Next, , it shows a pressure plate and diaphram spring. That's one fused unit rather than two separate parts in Porsches. The other thing is the release fork shown in the illustration is a heavier arm that's mounted vertically in Porsches.

[mgfranz]

Originally Posted by deliriousga

1966 Wife White/Brown Top
1986 Daughter White/Brown Top (Sold!)
1992 Daughter White/Blonde Top

Lol.... "Sold"?

Sorry, Monday humor...

[Mr. Boone]

Originally Posted by deliriousga

I don't have a lift. I use 6 ton SUV stands to hold her up. They have huge bases so they won't tip and I can raise it up 24". I used them on the 928 clutch and it was no problem at all.

For the special tool, I believe that article talks about supporting the engine from underneath. I always have a floor jack underneath, even with the stands, pressing lightly on the oil pan just in case so I'll put it where it can hold the engine up safely and even with the tranny. It doesn't look too hard to do with the whole thing coming out.

I'll be replacing mine along with a lightweight flywheel with inserts since the dual-mass OEM flywheel on mine is causing vibration. I'll let you know how it feels compared to the original whenever I get it done. I'm sure I'll be replacing it before you have to. Ours is a daily driver, 60-80 miles/day so it probably won't be long.

Thanks Again for the reply. I think 24" of jack stand would allow enough clearance as well. Might have to build up the car to that level as I don't think my floor jack has that much travel, but I am sure it can be done. I have now read the article you refered me to and it is quite good. I think the job can be done in a day as well. I guess I am just looking for some genuine symtoms before I go to the time and expense. The dealer warns me that if I wait too long I could damage the flywheel for an added $1K in parts..... probably just a bit of a scare tactic.