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Old 10-21-2012, 05:51 PM   #1
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Someone replaced my clutch pedal with a wet sponge

So I have 105,000 miles on my 05 2.7L 6-speed Boxster with the original clutch. Recently the clutch started slipping under "normal" circumstances. Before I really had to do something stupid to get the clutch to slip. Now a brisk WOT shift into 6th would slip unless I let off briefly. I was planning on ordering the clutch kit and replacing it over thanksgiving.

That was until yesterday...

I was on my way to head up to a date in San Francisco and all of a sudden the clutch goes spongy. It feels like it never fully disengages and has zero feel. Feels like I'm stepping on a wet sponge. It slips easier it seems and is hard to take off from a start, especially on a hill... remember the SF part?

So it didn't explode on my and today I bled the slave cylinder hoping that would be the solution so I could at least drive it.... nope!

Now I am trying to figure out the possibilities of what has gone south so that I can order parts in one shot. And I don't want to replace the clutch to find out the problem is still there and the master cylinder is dead. Now if I had more positive cash flow I would just replace everything for good measure. Sadly cash is not freely flowing right now so I need to keep it to parts that are actually worn out.

I did have an issue with my 944 where the release lever pivot backed out and it felt similar.

Has anyone else had this issue? I also thought about a light weight flywheel but that is a whole nother can of worms.
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Old 10-21-2012, 08:08 PM   #2
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Sounds like a loss of hydraulic pressure, slave cylinder may be bad, check for traces of fluid on floor.
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Old 10-21-2012, 09:18 PM   #3
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When I bled the slave all the dust that I could see was dry. I did get a bit of air out though. Being the cheapest part I will replace it and try again. No drips on the floor. This car has yet to leave a drop of any fluid on the ground the entire time I've owned it.
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Old 10-21-2012, 09:51 PM   #4
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Quote:
Originally Posted by 944boy View Post
When I bled the slave all the dust that I could see was dry. I did get a bit of air out though. Being the cheapest part I will replace it and try again. No drips on the floor. This car has yet to leave a drop of any fluid on the ground the entire time I've owned it.
If you're clutch pedal felt nearly perfect before, there was no air in the system.

Air leaking in is the cause of... well... A leak. lol

Its very possible it only leaks under pressure and very very slowly. Having room for pressure to escape will cause your pedal to feel like nothing.

The slave and master cylinders list at ~$250 together for OEM parts. For that kind of money, it may be worth the hassle to replace both of them. If you need to do a clutch anyways, do all 3 and your pedal should feel like a million bucks
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Old 10-22-2012, 03:12 AM   #5
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NOTE: if you buy a slave you will also have to buy a new line and connector as they are not a direct replacement any more.

Originally I had ordered the slave and master cylinder but failed to notice that you have to order two additional parts. The little connector and new line added $320.00 to the build bringing the upgrade of just the slave to over $400.00. Porsche is mighty proud of these parts.




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Old 10-22-2012, 03:14 AM   #6
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You drove on a bad clutch way too long, so why suspect the hydraulic system? It may be your clutch disc coming apart and jamming thing up. You'll probably need a new flywheel. I hope you're not still driving it.
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Old 10-22-2012, 04:20 AM   #7
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Check your clutch….original at 105,000 - you have been on borrowed time for a while. Surprised it lasted this long. However, it IS most likely DOING DAMAGE each time it is being used. Time to get out that secondary car (we ALL HATE that part). Get this puppy to the doctor STAT!
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Old 10-22-2012, 04:50 AM   #8
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Had my clutch replaced a month after owning the car, after 86K the clutch disc was just getting down to the rivets. I might of gotten another 5K out of it. (maybe)
You got 105K, you were driving on borrowed time.. I would suspect you reached the rivets on the clutch disc...
I would not continue driving it..
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Old 10-22-2012, 05:13 AM   #9
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So how did the date go? I used to live on Mason and Broadway... I can't imagine trying to navigate the inner neighborhoods of SF with an iffy clutch (not to mention, flywheels are too expensive to risk destroying)

Seem that a blown clutch is a great excuse to "spend" the night!
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Old 10-22-2012, 12:27 PM   #10
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@eric The old one looks like a 6-speed part, the new one looks like a 5-speed part. I just ordered a drop in replacement for $45.

One reason I think this clutch lasted forever is that it is all "s" parts even though it's bolted to a 2.7L. Friction material could have come loose, I will find out when I pull it all apart tonight. even if the rivets have not dug into the flywheel it might still be worn due to being a 2-piece design. replacing might be inevitable.

@Shadrach The date went well. Not the first date so having to baby the car was OK. I tried to avoid going UP hills and tried to avoid stopping. both very difficult. Taking the Motorcycle next weekend.

Now while I have the tranny out I will probably change the fluid, other than factory any recommendations? I like swepco and redline and motul in 944's. Not necessarily looking to save money.
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2005 987 - 112K miles PASM + 6-speed - Daily Driver
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1974 911 Targa - new project
2009 Triumph Street Triple R - 27K mi - Blazen Orange
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Old 10-24-2012, 10:21 PM   #11
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I will upload more when I have some light. But chew on this! The disk seems to have plenty of meat. Not even close to the rivets. Looks like a combination of the pressure plate and throw out bearings failed.
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2005 987 - 112K miles PASM + 6-speed - Daily Driver
1988 944 - 240K miles- Race Car
1974 911 Targa - new project
2009 Triumph Street Triple R - 27K mi - Blazen Orange
1976 Ford F250 camper special - tow vehicle

Last edited by 944boy; 10-25-2012 at 08:58 AM.
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Old 11-01-2012, 06:27 AM   #12
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fwiw, i went thru this same drill.... clutch had 160k and had plenty of life left in it.
the slave cylinder required the new line and adaptor at a rediculous price, if you take the part # from the old one you can buy it on ebay for about $40, says it is for a VW Jetta, my problem turned out to be a cracked pivot arm and it was flexing under load, suggest you inspect it carefully



Last edited by oldboxster; 11-01-2012 at 06:32 AM. Reason: rearrange pic
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Old 11-01-2012, 08:40 AM   #13
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My pivot arm is fine. I am waiting on the last few parts to come in so I can take some comparison photos. The throw-out bearing was quite beaten up and the pressure plate had lost all clamping force. I'm not sure the slave is actually bad though. And for the 6-speed its quite easy to locate a direct replacement.

Sad part is I had to bite the bullet and order a new flywheel, the old one would not return to center when rotated.

Can't wait to get it back on the road though, 2-weeks is among the longest it has ever sat idle!
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2005 987 - 112K miles PASM + 6-speed - Daily Driver
1988 944 - 240K miles- Race Car
1974 911 Targa - new project
2009 Triumph Street Triple R - 27K mi - Blazen Orange
1976 Ford F250 camper special - tow vehicle
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