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Old 10-29-2014, 01:03 PM   #1
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Clutch got heavy

My clutch all of a sudden feels different. Its feels heavier.

There is no problem shifting, jut it seems to need more pressure to push it in and it comes up faster as well.

In looking at the parts diagrams, I think it may be related to the booster spring #9.
Does that spring push or pull? In other words does it help push the clutch pedal down for less effort or does it pull the pedal back up

I do remember hearing a squeaky/clicking sound when I put in the clutch and that sound is now gone.




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Old 10-29-2014, 01:09 PM   #2
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I've noticed Germans love making self adjusting clutches, something you could read on to see if it applies to your car. I quickly searched Google and it looks like it applies to certain Porsches. Maybe your self adjustment was stuck and it suddenly adjusted?
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Old 10-29-2014, 01:48 PM   #3
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Self adjusting I believe applies to non-hydraulic clutches

My clutch works fine, same engagement spot, etc. just requires more effort
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Old 10-29-2014, 02:25 PM   #4
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Quote:
Originally Posted by JayG View Post
Self adjusting I believe applies to non-hydraulic clutches

My clutch works fine, same engagement spot, etc. just requires more effort
I've only personally seen it on non-hydro, but a little more reading on Google says Porsches self adjust with the pressure plate. I found a thread on a Cayman being self adjusting, I can't say if our cars have the same thing.

Maybe the mechanism that self adjusts made the pedal feel stiffer somehow, I have no other ideas as to what would cause that.

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Old 10-30-2014, 04:29 PM   #5
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It was a broken clutch booster spring

I pulled it and the spring was broken in 3 pieces

Dug through some forum posts (rennlist 996 and BoxA) and was able to just replace the spring.
the whole part from the dealer is $102. I put in a spring from Home Depot $4.00. That spring is a little light, and I will order a stronger spring online, ~$ 10.

Its a pretty easy DIY, just you have to wiggle under the dash on your back

Here is a great DIY thread on Boxa
How to - 986 Clutch assist spring replacement - How To - www.BoXa.net

My Bentley and the online workshop manuals were useless

only problem I had was when I was putting it back in, the mounting bolt dropped into the clutch pedal (yes, it is hollow). I was able to push it back up and out with a small magnetic pickup tool. other than that, pretty easy
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Last edited by JayG; 11-03-2014 at 10:29 AM.
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Old 11-03-2014, 09:32 AM   #6
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Good info.

Quote:
Originally Posted by JayG View Post
It was a broken clutch booster spring

I pulled it and the spring was broken in 3 pieces

Dug through some forum postes (rennlist 996 and BoxA) and was able to just replace the spring.
the whole part from the dealer is @102. I put ina spring from Home Depot $4.00. Thaty spring is a little light, and I woll order a stronger spring online, ~$ 10.

Its a pretty easy DIY, just you have to wiggle under the dash on your back

Here is a great DIY thread on Boxa
How to - 986 Clutch assist spring replacement - How To - www.BoXa.net

My Bentley and the online workshop manuals were useless

only problem I had was when I was putting it back in, the mounting bolt dropped into the clutch pedal (yes, it is hollow). I was able to push it back up and out with a small magnetic pickup tool. other than that, pretty easy
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Old 11-03-2014, 10:30 AM   #7
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One more "trick"

If you remove the bolt connecting the pedal to the clutch arm, its much easier to remove and install the booster spring. That bolt is very easy to remove and reinsert
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Old 11-11-2014, 08:40 AM   #8
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UPDATE....

The Home Depot spring was way to weak and IMHO did not give enough push

From what I have read, the factory spring is around 52 lbs/inch spring rate and the Home Depot one is ~25 lb/in.

I got a used replacement one from itsnotanova (Search for him on this forum) for $15 shipped and it is perfect! I did find a new spring that was close, ~40 lb/in, but decided to go with the factory spring instead

Much better feel with the stronger spring.

FYI, you do not need the spring at all if you prefer a "heavier" clutch

Also , the circlip broke that holds keeps the bolt (#8 in diagram) from sliding out. I just replaced it with an E clip, works perfectly

Thanks again Woody
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Last edited by JayG; 11-11-2014 at 08:46 AM.
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Old 11-11-2014, 09:55 AM   #9
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My clutch is super heavy and I haven't driven another Boxster in over 2 years. There is a 2nd one scheduled for the Autocross this Sunday, I may do a quick comparison and if it is much lighter I may make this change as well. I have gotten lots of parts from Woody, always top notch.
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Old 11-11-2014, 10:26 AM   #10
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With the spring in place, the clutch is very linear in pressure up and down. without the spring, it wants to pop back up.

Its likely the spring broke.

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