Clutch Helper Spring Banging SSI

[piscator]

I tried to install my clutch release lever today, but the ‘helper spring’ (what Porsche calls the auxiliary return spring) won’t clear the heat exchanger on my new SSI’s.

As you can see in the photos, if I line up the spring so it can slide over it’s appropriate pin, it hits the bottom of the SSI when I try to push home the clutch release lever.

If I rotate the ‘helper spring’ in a way that lets me push home the clutch release, I can’t get the spring onto the pin.

That whole corner of the SSI is blocking the ‘helper spring’. If I dropped the SSI to install the spring and release lever, there would be room between the SSI and the spring to accommodate reinstalling the SSI.

The only fix I can think of is some sheet metal modification to the SSI heat exchanger. I had to do a bit of this to fit the crossover oil line. But, before I break out my hammer, I thought I’d ask if you guys agree or have faced this and found another solution.

If it’s not one thing, it’s another… right? :-)

[darrin]

Backdating an SC to SSI - Interferes with Omega Spring

[theiceman]

helper arm is supposed to be stopping against this tab , make sure arm is not going past it as the tab may have worn out.

personally i dont think its working because of all the grit and grime in the way ,,,,

[proporsche]

i was just about to say iceman;-)your arrow is nicer;-)-----Robert, remove the L shape bracket and make it again L .The shaft of the spring have to stop on it once done.
Also how far did you put the clutch cable into the front clevis?Does it go a little past the threads -like 5mm?
If not you have to correct it...

Ivan

[john walker's workshop]

You will need to flatten the lip with a hammer and maybe a bit more to get final clearance.

[pmax]

Pisca,

As Mr Walker said, time to put the BFH to work !

[piscator]

Super helps, guys! Thank-you!

Darrin, I think I remember that thread, but really appreciate you’re linking it.

Iceman, there was no way that spring was going to snug up to that tab without the modification shown in the photos below. BTW: Your gearbox looks far more legitimate than mine! :-)

Ivan, you’re right that Iceman does draw nice arrows! I think you guys were on the right track, but we still needed the Walker modifications. The cable isn’t connected to anything, so it’s not playing a role in this drama.

Pmax, you are correct, Mr Walker knows his stuff!

John, when I first joined this board you helped me devise a gearshift extension. I’ve always appreciated that and learned a lot from all your posts. I don’t remember what thread it was in, but recently, I’ve latched on to a quote of yours which I absolutely love and have borrowed (with attribution, of course)!

You wrote:

“We’re mechanics, we’re supposed to fix stuff!”

I love that!!

Thanks again!

[911 Rod]

I didn't think you had to bang it in that much.
Did you split the seam?

[proporsche]

why the heck did you this??the shaft is not even touching the bracket the way you have it?????
It is wrong dude!!connect the cable then worry about the clearance on the Omega spring..mama mia;-)??You are way past the stop point of the clutch arm.....and the clutch cable travel...

Ivan

[pmax]

Looks similar to this, done at a shop.

SSI Installation

[piscator]

Good Morning Guys,

Ivan, If I've screwed up, it certainly isn't the first time and it's not likely to be the last! What I did, I thought, corresponded to what I found in the thread Darren linked. I positioned that spring in every orientation I could think of but I'll work on it again today.

Rod, No, the seam didn't split at all -- I banged it pretty carefully. If I screwed-up, at least it's a nicely executed screw-up!

P, thanks for hanging in and for the link. This situation reminds me of my other favorite mechanic quote, this one from Dan Jacobs on the subject of having to re-do an incorrectly installed timing chain tensioner:

"It's just a machine"

If we foul up, we take it apart and fix or replace it.

[john walker's workshop]

Where is the short arm?

[MBAtarga]

You've split the header open:

[proporsche]

yup it is time for some crafty welding ;-)

Ivan

Robert, assemble the whole thing together then you can do the correct adjustments.Make sure you connect the cable up front as i told you earlier.It will give more play in the back for adjustment.
Then report back...........

[Nditiz1]

Those SSIs are trashed. Please send to me and I will dispose of them >;-p

Nothing a quick weld can't fix.

[eastbay]

Originally Posted by MBAtarga

You've split the header open:

It's just the airbox, let's not get hysterical here.

[theiceman]

holly crap dude !!!!! even just a spot of weld on that L braket would have done everything you needed. Thats what i had to do as i could not get mine off to repair it . My buddy pit a spot of weld on it. i filed it down and presto, the helper arm rests right against it.

But no point in kicking a man when he is down. it will all work out and you will be the only one who knows about it

[Geronimo '74]

Originally Posted by john walker's workshop

You will need to flatten the lip with a hammer and maybe a bit more to get final clearance.

I did this, problem solved.

[David Inc.]

That omega spring should look like the below. You have yours on the wrong side of the stopper...if you try to put the clutch pedal down that stopper will halt the action of the helper arm.

[piscator]

Good Afternoon Gentlemen,

Ivan, I really appreciate your setting me straight! You were, of course, correct. I screwed up! Mia Culpa!

To be honest though, it's not bothering me all that much. Most everything I've ever learned came out of an experience of making a mistake.

Interestingly, while I certainly banged it too far, when you look at it on the car, the symmetry does suggest that Dansk/SSI probably should make that corner differently. Glad I could do some testing for them! ;-)

I know some guys at a good welding shop who can fix this. It's not that big a deal to drop that SSI for repair. I'll stop in and ask what they think.

As always, thanks for everyone's help. You guys are great!