clutch suddenly stiffer - dead helper spring?

nostatic · nostatic's Garage

Upon getting my car back yesterday I noticed that the clutch pedal is stiffer and more linear (doesn't have that sort of snappy feel). I'm assuming this is a classic symptom of a broken/dead helper spring?

The clutch cable only has about 15K miles on it, but it is about 15 years old, so I'm thinking I should replace the cable and the helper spring. According to 101 projects this doesn't look *too* bad...viable DIY for a man of limited hands?

Sonic dB · Sonic dB's Garage

nostatic, its probably not the clutch cable and more likely is the helper spring. It could be clutch cable, but unlikely. Either way, its only a $60 part to swap out.

RoninLB · 07-12-2003, 10:44 AM

I would try a proper adjustment if the pedal helper, and auxiliary spring are intact.. adj the pedal stop so that clutch travel is a total of 25mm +/- .5mm... if it still feels heavy then probably a thin/worn clutch disc............Ron

nostatic · nostatic's Garage

Ron, I don't think it is a worn disc, as the clutch only has maybe 15K on it, and the feel changed literally overnight. It originally had a non-constant feel (like it it hardest to push in the middle of the stroke and springs at both ends), although I noticed it started feeling a bit off recently. Now all of the suddent the feel is stiff and constant through the throw. I haven't been able to take a peek underneath yet to see if the spring has any obvious issue or what the travel is (too low to crawl under and I don't have a floor jack or stands).

pbs911 · pbs911's Garage

Adjust the clutch. A stiff peddle can also be the result of gunked up clutch cable and worn peddle bushings. Even though there are not many miles, the years take their toll on the plastic parts. I doubt a piece of metal (horeshoe) broke. The mileage on a clutch has nothing to do as to whether it is bad or good. I have heard of people going through clutches in 5,000 miles and others 100,000 miles. Did the PO change out the clutch in yours? They must have if it's only 15 years old. If so the PO wnet through clutches pretty quickly. How fast a clutch wears depends on the driver, how well adjustment is maintained and how the use.

nostatic · nostatic's Garage

The PO did change the clutch, but that had the infamous rubber-centered clutch. It was changed in '90 as I recall with about 38K on the clock.

It shouldn't be me burning through the clutch, as I've always gotten well over 100K out of every other car/clutch I've owned. Then again none of them were 911s...

Jim Richards · 07-12-2003, 08:44 PM

Todd, did you look under the car yet to see if the helper spring is broken?

nostatic · nostatic's Garage

I tried but I couldn't see. My car is pretty low, and I don't have a floor jack. I could see the other spring, but couldn't see the omega-helper one.

I did notice some new oil leaks though...its about time it became a real 911.

speeder · speeder's Garage

When the helper spring broke on mine last summer, it was not a *subtle* difference. It went from normal to almost impossible to depress clutch, not just a "little stiffer". Hope that helps as a data point.

Jim Richards · 07-12-2003, 09:03 PM

Quote:

I did notice some new oil leaks though...its about time it became a real 911.

That's good news, Todd. Oh wait, maybe it isn't. Oh, never mind.

Assuming it turns out to be a broken helper spring, I'm not so sure you need to replace the clutch cable, too. Since you're probably dying to find out if the spring is broken and you're just starting your "career" chasing oil leaks, you'd better pony up some $ for the floor jack and jack stands! Good luck and have fun.

nostatic · nostatic's Garage

yeah, I just looked and I don't think I'll go broke buying a floor jack and a couple of stands.

According to Bentley the clutch cable has to be pulled to get the spring off (so might as well replace it), and 101 projects also mentions possibly needing a dremel tool. Luckily with a 6 year old boy in the house we have lots of bandaids on hand...

Chuck Moreland · 07-12-2003, 09:47 PM

Out of adjustment can make the clutch feel very heavy. Almost an amazing difference. No, let me rephrase - an amazing difference.

But since yours changed overnight, I too would suspect the spring. I'd go ahead and replace both helper springs, horshoe and the one at the peddle.

FYI, I've had bad horshoes that were not visibly broken.

Schrup · Schrup's Garage

Harbor Freight is a great place to check for stands & a jack. I picked up 4-3ton stands for $10 a piece & a aluminum race jack (35lb) for $160.

Jdub · 07-13-2003, 07:26 AM

If you don't know the history on the clutch cable do yourself a favor and change it. The helper spring is easily checked for break - lift the car and have a look or just put one wheel on a curb and backstroke under the car.

You might consider a rebuild on the pedal rack, and get yourself a fresh clutch spring at the pedal rack at the same time.

The combination of replacing all three of these components (total price about $200.00) is amazing. Feather-soft clutch and great action.

John

sammyg2 · 07-13-2003, 08:53 AM

I changed the clutch spring at the pedal a while ago, mine was broken and the new one made some difference, but not dramatic.
Sure was a PITA to install without pulling the entire pedal assembly.

my point? It could be either spring, the one at the tranny makes a huge difference, the one at the pedal makes a small difference.