Rebuilt 915 clutch cable gap set up problem

[Classic11]

Hey, I am trying to set the clutch cable on my new 915 tranny (new clutch, pressure plate, throw out bearing, release fork, cable) but no matter how i connect the spline i cannot get it to work. Either the screw is too short or i cannot get it in there, the picture explains it best. Should i use a longer screw or grind the arm off a little or what else could be the problem?

[r lane]

At the end of the long arm, there is a pin that should be up against a stop. That secures the long arms location. The short arm contact spot should be approx. 1/4'' off the face of the long arm. I have to think something may be amiss inside the bell housing. Release bearing fork alignment on the shaft, held in by a roll pin.

[Jonny042]

Not sure if this will help. Here's mine, fresh from the "to be cleaned" pile.

Not sure who's is assembled wrong, but one of them must be...

[Jonny042]

Also, I checked and the splines are the same on both ends of the shaft, so its not like you can clock the splines to different positions like you do with torsion bars. So you can't solve it by pulling the motor and trans out

[proporsche]

classic..you have to pull back the arm with the Omega spring with a big screwdriver then instal the little finger and adjust the gap...
Ivan

[Classic11]

I think i could move the nut to the inside and the bold could be long enough to get me to 1mm gap. I even checked the splines on the shaft before assembly and saw the same thing. When the clutch wears the gab will get smaller and the situation better, so maybe its just because everything is new and the way tolerances fall.
I thought pushing the clutch down a few time would make things align but it did not change anything either.

[Classic11]

proporsche, but the big arm rest against a stop, if i push it back i just push against the stop.

[yelcab1]

Show a picture that includes more surrounding.

[proporsche]

classic..no the arm has to be pushed the opposite direction towards the cross over exhaust pipe..
like this..........then you install the little finger with return spring on it....on this pic the adjustment on little finger is not done yet

[Classic11]

propoorsche, when i push the big arm to the right in your picture i will push it against the stop, when the clutch is not in use the spring will push that big arm back to the stop. Only if I somehow move the stop farther towards the exhaust this would help. Maybe i can loosen the two bolts of the bracket and see if there is some room to move it some then tighten it again abut i don't think there is engouh.

[proporsche]

again the little finger comes on later after you pull the arm back direction exhaust.....on then you install the little finger...use a bar or big screwdriver...

[Solamar]

Originally Posted by Classic11

I think i could move the nut to the inside and the bold could be long enough to get me to 1mm gap. I even checked the splines on the shaft before assembly and saw the same thing. When the clutch wears the gab will get smaller and the situation better, so maybe its just because everything is new and the way tolerances fall.
I thought pushing the clutch down a few time would make things align but it did not change anything either.

Are you confident the release fork "fingers" are correctly in the throw out bearing groove? Fingers behind the throwout bearing might cause your problem.

Pictures just for reference -

[Solamar]

Originally Posted by Classic11

propoorsche, when i push the big arm to the right in your picture i will push it against the stop, when the clutch is not in use the spring will push that big arm back to the stop. Only if I somehow move the stop farther towards the exhaust this would help. Maybe i can loosen the two bolts of the bracket and see if there is some room to move it some then tighten it again abut i don't think there is engouh.

There is no adjustment in that bracket, and your release lever (13) looks to be in the correct location (angle relative to trans).

[Classic11]

Just to follow up, i moved the nut and it worked out well, It does not look as much "off" now as it did. I know the fork is in the release bearing as i checked it after i pushed the tranny on the engine. thanks for all the input and advice as always, great forum and people.

[proporsche]

the little finger is in wrong place you should remove it and reposition it....there cannot be so much space between the arm and the finger...also the bolt is too long get the shorter ...
Ivan

[Kool-aid-82]

Originally Posted by Solamar

Are you confident the release fork "fingers" are correctly in the throw out bearing groove? Fingers behind the throwout bearing might cause your problem.

Pictures just for reference -

I suspect this ^^^^

[pmax]

Originally Posted by Classic11

The instructions are written based on the OEM bolt. Replace that first.

[yelcab1]

For some reason I seem to recall that the omega spring goes the other way. In a Carrera, it fits against the heat exchange with a cut out in it. Which means your omega spring is in either 1) backward, or 2) not pushed against the exhaust far enough.

Once you have done that, I think the arms will line up fine.

Find another picture of a Carrera with an installed omega spring to see if you have it correct.

[boyt911sc]

Classic,

The clutch positioning lever shown in your picture is out of position. There is too much angle or space between the clutch positioning lever and the clutch release lever. See pictures below:





Compare the relative position between the two (2) levers and you will see the big difference. The backsides of the levers are almost parallel to each other.

Tony

[gomezoneill]

I think Porsche over engineered this clutch release setup. Could've been much simpler.