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The Glademister's Avatar
 
Join Date: Dec 2007
Location: On a winding, hilly road in Tennessee.
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2242 miles on a sports clutch and failure

Now we're talking ridiculous...

For those of you that followed my thread here...

Sports clutch install -

...that procedure and everything that followed was brutal (and expensive). For those of you that didn't read - basically we pulled and original clutch and flywheel at 55,000 miles and replaced with the Fuchs sport friction disk, sport pressure plate and LUK dual mass flywheel (see the photos in that original thread). We then went through a series of issues with leaks that were unrelated to the clutch job (except leaving out the main shaft seal in the transmission) but the car was never driven long enough during the leaking to splash those components with oil. But after 2200 miles I lost the clutch completely at an autocross event. So yeah, I autocross the car (we did three events before failure) and daily drive once or twice a week to work. When I autocross this Cayman S, I put on 18" wheels with 285 and 245 Hoosier A2 tires. If you look at the attached photos you'll see what the friction plate and flywheel looked like when we pulled them. The friction plates material has flown off from the outside edges. It was a different material than the OEM plate had. Much like fiberglass and had imbedded itself into the pressure plates inner areas. Maybe clogging enough to prevent the spring "fingers" from releasing properly. The flywheel was heavily scored and burned. Fuchs states in the sales info that the sport friction plate is made of "organic" material. What's that supposed to mean?






Anyway... we've gone back in and put in OEM friction plate, pressure plate and another flywheel. That's another $1000 in parts. Thank goodness I'm getting free lift time and have a good buddy who joins me in doing this work. This was our 6th time taking the transmission out. We had it out, components replaced and back in - 3 1/2 hours.

So moving forward, what can I expect? I'm going to continue to autocross this car (two more events planned this year) and I have to run those Hoosiers to be competitive. Is it the extra grip and mass that's causing excessive wear? Surely Porsche would expect end users to add more grip! Some will say "always dump the clutch" but can you really do that in slow traffic or elevated parking garages?

A long time autocrosser and engineer saw the exposed clutch and flywheel while we had the car car on the lift. He commented that the clutch looked really small for that size transmission and engine. And I know from changing a clutch on a 2.5L Boxster that it's basically the same size on a 3.4L Cayman S. A design flaw on Porsche's behalf?
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Current projects - '14 Cayman, '06 Cooper, '73 914 2.0L, '99 Boxster, '07 Cayman S
Past projects - '72 Opel GT, '75 280Z, '90 300ZX, '87 944S, '87 944 Turbo, '88 924S (x2), '02 Boxster
Old 07-03-2012, 08:12 AM
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Wow that sucks, where did you get the parts? I would go back to them and explain it to them, i tend to ride the clutch a bit in different scenarios, but i expect 40-50 k mids out of them, and that is autoXing and track days
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Old 07-04-2012, 06:39 PM
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Quote:
Originally Posted by stealthn View Post
Wow that sucks, where did you get the parts? I would go back to them and explain it to them, i tend to ride the clutch a bit in different scenarios, but i expect 40-50 k mids out of them, and that is autoXing and track days
I purchased from a trusted vendor (who's actually giving me a small discount). I don't believe it was the vendors fault. My concern is for others who think this Fuchs sports clutch material is going to be superior to the non-sports. After seeing how the friction disk deteriorated so quickly - my opinion is, it is not.
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Tennessee Region SCCA & PCA
Current projects - '14 Cayman, '06 Cooper, '73 914 2.0L, '99 Boxster, '07 Cayman S
Past projects - '72 Opel GT, '75 280Z, '90 300ZX, '87 944S, '87 944 Turbo, '88 924S (x2), '02 Boxster
Old 07-05-2012, 03:16 AM
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Update - One year later, a half dozen autocross events, once a week daily driving and the OEM replacement clutch is doing fine. I'm convinced that the sports clutch friction material is garbage. I can't image why Fuchs would market a product like that as better than OEM.
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Tennessee Region SCCA & PCA
Current projects - '14 Cayman, '06 Cooper, '73 914 2.0L, '99 Boxster, '07 Cayman S
Past projects - '72 Opel GT, '75 280Z, '90 300ZX, '87 944S, '87 944 Turbo, '88 924S (x2), '02 Boxster
Old 07-29-2013, 12:36 PM
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Old 07-29-2013, 12:36 PM
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