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Old 01-04-2015, 05:47 PM   #1
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Technical Difficulties after clutch job

Hello Everyone,

I just put together my car after a clutch job and unfortunately have fouled something up with the job. I'd greatly appreciate any pointers on what to look into before paying a professional. I'd like to try and finish what I started!

Here are the main components I purchased:

1. LUK Part # DMF025 Flywheel
2. SACHS Part # K7019301 clutch and pressure plate
3. Pelican Parts IMS
4. Cat Bypass Pipes
5. New Transmission with less miles was installed ( had it available so figured why not...could one 2.7L tranny be that significantly different than the other? I was told when purchased it was from a 2001-2003 2.7)


Here's what happens when I start the car while on jack stands:
1. Car idles at about 900rpm

2. Can apply gas with no issues when not in gear

3. Once I try to place car in first gear and maintain about 1.2k rpm it sounds normal for about 4 seconds and afterward I hear a big bang that feels like something is off-balance / and or like two metal items colliding. I can feel it from the drivers seat rather well..it's bad.

3.5 When I disengage the clutch after the noise occurs you can abnormally hear the disengagement. I never heard it previously.

4. Clutch hydraulics are different..the pedal allows me to switch gears but it sits much lower than it previously did.

I made a sound clip but it wasn't an allowed format. Will make a video tomorrow.

Question: Could this be due to not mating the clutch and flywheel?

Question: The axle shafts are about 50% torqued..could that cause this noise when I put it into gear?


Thank you for your time!

-Bennett
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2001 Porsche Boxster Base in all Black at 102k

DIY work so far:
- Row Kit, Tie Rods, Drop Links, Elephant Racing Control Arm Bushings, Water Pump replacement, IMS guardian, 968 Sport Seats, and Axle Shaft rebuilds.

Last edited by grimesb; 01-04-2015 at 05:51 PM. Reason: spelling
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Old 01-05-2015, 01:07 PM   #2
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Can you get someone else to operate the clutch while you get your ear under the car?
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