Clutch cable clevis pin removal - argh!

[Otter74]

I feel a little self-conscious asking so many questions without having contributed very much yet, but, well, I'm still learning my 911! I'll have something to contribute after a couple of my projects later this summer.

The other weekend I adjusted my clutch, since it was a bit off. I have a new cable and wanted to replace it, but couldn't. I plan to replace it this weekend. Couldn't replace it because I could not get the clevis pin/retainer out. Obviously it's tight down there, but even given that condition it was a PITA. My pin/retainer is installed such that the retainer swings down, which means that the open side of the pin is on the tunnel side of the car. If it were on the driver's side, mounted so that the retainer clip swung up, I could hit it the pin with a punch/screwdriver/whatever and hammer to get it started on its way out. But since it's hidden on the backside, I can't.

I have searched through a variety of existing clutch cable-related threads.

How the hell can I reasonably get this off? I do have a new pin/retainer (but not clevis) to install with the new cable. I did shoot some PB Blaster on the pin/clevis, though that hasn't helped yet. Any good tips I'm not thinking of?

Also, I am missing a footboard entirely on the driver's side. I picked up a used OE one, though I may end up just getting a new one. I am not sure what else I need. I know I need a clutch stop (back of the footboard) and its rubber bumper, and I have those part numbers. I am not sure exactly what I need for the bottom of the foot board. My foot board is missing the riveted bit on the bottom that helps attach it to the pan - is this available on its own? Is that, and a nut and washer, all I need? I can't find it on our host's site. The only thing I've got on the floor of my car is a screw coming up from the bottom side of the pan.

[DRACO A5OG]

Yes, a BIG PITA, the pin may have sheer or worn grooves causing it to bind and so much rooom to work, right?

I had to keep working at it, twisting up and and down and finally it broke loose.

Post a pic and maybe we can see the trouble???

[juanbenae]

break the thing off and buy a new one. they are cheap and not worth the time.

[john walker's workshop]

A screwdriver in the clevis and pry to spread it out enough to get it off. New clevis and pin. You can only spend so much time head first down there before resorting to drastic measures.

[Discseven]

Originally Posted by john walker's workshop

You can only spend so much time head first down there before resorting to drastic measures.

HA!!!! Agreed. That ranks among the worst areas of a 911 to work in (unless driver's seat is removed---which come to think of it is not a bad idea.)

Am skipping how to get clevis out and commenting on position of new clutch cable... Check new cable's position inside tunnel to ensure it is not wrapped around "other things" in tunnel.

[Targa Me]

Yup, they're a PITA.
Use a screwdriver as John W. suggested.
Take your time and breathe deep.

As Charles Freeborn says, "A good sense of humor is the best thing to have in your toolbox when working on these cars." <--- Removing and replacing that clevis is where this quote comes in handy.

[Otter74]

Thanks, John. You mean just pry the clevis arms out far enough that one side comes of fthe pin, then remove and replace it all? Not sure, but it sounds like that's what you're saying.

Originally Posted by john walker's workshop

A screwdriver in the clevis and pry to spread it out enough to get it off. New clevis and pin. You can only spend so much time head first down there before resorting to drastic measures.

Today or tomorrow I am going to try some more lube and see if I can reach it from the passenger footwell to hammer the pin out. If not, I'll save the job for next weekend and get a new clevis in the meantime.

And thanks, discseven, for the reminder on the position of the cable. My current cable is wrapped around the throttle cable.

[john walker's workshop]

You break it by spreading it apart, basically. The pin often gets a notch worn in it which requires the clevis be moved forward a bit as you try to remove it so the pin doesn't hang up on the pedal lever.

[gomezoneill]

Disconnect the cable from the trans first to relieve tension on the cable.

[redstack]

+ 1 on removing it from the trans first

[Jdub]

I guess it won't help to hear it, but now is the time to rebuild your pedal assembly, and to replace all bushings in your shift lever assembly back to the coupler. The difference is to feel what Porsche had in mind when the parts are new. It is pretty impressive and will add miles and miles to your transmission.

Good luck! You have a pin that has dug into the clutch "ear" after having worn through the brass bushing. You absolutely MUST have a new brass bushing in hand when you put this all together.

[Whit]

Originally Posted by Jdub

I guess it won't help to hear it, but now is the time to rebuild your pedal assembly, and to replace all bushings in your shift lever assembly back to the coupler. The difference is to feel what Porsche had in mind when the parts are new. It is pretty impressive and will add miles and miles to your transmission.

Good luck! You have a pin that has dug into the clutch "ear" after having worn through the brass bushing. You absolutely MUST have a new brass bushing in hand when you put this all together.

+1 Rebuild with Brass bushings. One of the best and cheapest updates.

[Otter74]

Thanks for the reminder on removing it from the transmission end first to take the tension off. I don't remember whether I did that the other weekend, but I may not have.

Jdub, which bushing are you referring to? I don't remember there being one at the arm that the Clevis and pin attach to. I already replaced all my shifter bushings Last year; I think the pedal box feels fine, but am checking with the PO to see if he rebuilt it. He rebuilt practically everything over the 15 years he had the car.

[Jdub]

Otter - there is a super-small brass bushing in which the pin rotates. That bushing actually sits in the hole on the pedal rack side of things. The purpose is to both protect the metal-to-metal contact and to make the action easier as the pin rotates on use of clutch.

http://forums.pelicanparts.com/uploads13/DSC014921215642461.jpg

Take a look at the pic here to see the result: http://forums.pelicanparts.com/uploads3/P10100021086137618.jpg and http://forums.pelicanparts.com/uploads13/DSC014821215642438.jpg.

If you do not see the bushing it has probably been allowed to disintegrate, which tells you if the pedal rack was ever rebuilt (probably not). This is why I recommend you be sure the work has been done as the difference is quite amazing.

[Otter74]

Jdub - thanks, now I see what you mean. I'll see what the PO says, and if it hasn't been rebuilt I might as well go ahead and do that.

Also, anything on the footboard? I checked down there yesterday and there is nothing at all to bolt a footboard to, except (arguably - I'm not sure this is what it's for) a screw sticking up from the bottom of the pan, under the clutch pedal pad to the left of the pedal box. I've been unable to find a photo in a thread here.

[911 Rod]

The pain!!
I did mine a couple of weeks ago only to realize I didn't have the cable turned in enough and had to do it again!
Don't make the same mistake I made as there will not be enough adjustment on the other end.
Bentley shows the clevis mounts from the top and 101 says from the bottom. The top is far more difficult to do, but makes more sense. The 2nd time I was out of patience and came from the bottom.

[Otter74]

Thanks, I doubt I would have thought of that. I will make sure to get the new one close to what the old one is at when I install it.

here is a photo of my footwell/pedal area. I see nowhere to attach a foot board.

[911 Rod]

There is only one stud to attach the foot board and it is at the bottom center.

[Otter74]

Originally Posted by 911 Rod

There is only one stud to attach the foot board and it is at the bottom center.

Sure, but as you can see, there's nothing bottom-center on my floorpan. There's nothing out-of-frame, either.

[DRACO A5OG]

Zoom out a little more please