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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".