broken clutch fork...or?

k9handler · 10-27-2005, 08:11 AM

Damn if isn't always something going wrong with the old 911.
Today I noticed that the clutch was not engaging very smooth and the pedal feel was not right...so I made a quick adjustment to the cable and it felt a little better but not much. Then on the way home from work it got even worse, except this time I could not engage any gear with the engine running. I disconnected the clutch cable only to find the arm is stuck as if the pedal part way to the floor.

Broken clutch for is my first thought, what do you think? Any other items to consider? Worst part is I know this means another engine drop and getting the resources/people together for that is not easy around here.

wilke3169 · 10-27-2005, 08:29 AM

Broken Clutch

K9, mine did this last winter. Broken clutch fork was the culprit. I ended up with a complete rebuild, clutch, etc while i was in there. But it does sound like yours has followed the same path of failure that mine did. Removing and rebuilding the shaft isnt bad although there are a few, hmmm so thats how it comes apart moments.
Good Luck,
Kevin

k9handler · 10-27-2005, 08:38 AM

thanks for the reply...this is not going to be an easy pill to swallow (wife does not know yet).

wilke3169 · 10-27-2005, 08:49 AM

Boxes? What boxes??? I actually think if I knew how much I spent while my engine was out I would be upset. Wife took a don't ask don't tell policy. But I didn't ask about the new living room furniture either. As far as the gathering of friends it was me all by myself.
We are gonna need more cowbell...

k9handler · 10-27-2005, 09:29 AM

yeah...more cowbell to cover the sound of screaming spouse!

This has not been a good year for vehicles, and I would be more than willing to tackle the repair solo but the 3.6 does not come out easy. It's a 2 person job at least.

k9handler · 10-27-2005, 10:25 AM

what about having the flywheel refinished? How long does it take...basically could I have it refinished and put back in the car same day? I think I may go ahead and get a new clutch throw out, clutch fork and go from there.

wilke3169 · 10-27-2005, 10:43 AM

Mine was done in a few hours. Local machine shop that does Porsche work.

Grady Clay · 10-27-2005, 12:19 PM

K9,

What is your transmission Type?

Another thing to check before pulling the engine is to inspect the clutch pedal arm, spring and attachment to the cross-shaft in the pedal assembly. The pedal arm-to-shaft attachment can be failing and give the same symptoms.

The risk always when the clutch linkage fails is that the syncros are overwhelmed and the syncro ring is damaged, the sliding sleeve and gear dogs are damaged. This would be a good time to drain the trans through a filter and pull the shift pivot for inspection.

As in the linked post, it would be good to list all the potential parts needed.

Pressure plate
Disc
Throwout bearing
Release bearing fork !!!! Role pin
Shaft, needle bearings?
Pilot bearing
Guide tube
Guide tube O-ring
Main shaft seal (need P381, P382 & P386)
Rear main seal (need P
9 pressure plate bolts & split lock washers
9 Flywheel bolts
Clutch cable
Clevis fork and pin
re-surface flywheel or have a new or resurfaced one handy. (You don’t know if a flywheel can be successfully resurfaces until during the machining process.)

CV bolts, Schnorr washers, gaskets.
Shift pivot gasket.
Transmission lube
Engine oil & filter
More?

JW posted “make sure you lube the main shaft splines and around the guide tube. inspect the guide tube for wear also. They’re dry as a bone, not good.
Inspect for any oil leak or other issues you want to attend to while the engine is out - - “

Let’s make a list
Clean the engine & transmission and the engine compartment and underside above the transmission.
Clean & lube the throttle linkage
Check for rubbing of any of the 3.6 fuel lines or signs of a leak.
Make sure the heater controls function correctly, replace flex hoses if nec.
Check CV boots
More?

While I’m thinking about it, What model year is your 3.6? Is it USA or Canada or other?

Best,
Grady

k9handler · 07:46 PM

Grady,
Thank you very much for your response. As I went to bed last night I did think of the arm itself and that it could be the cause. The tranny is a 1974 915 with NO helper spring, clutch cable is new as I installed it in July. Clutch has just over 1 year of use (Sachs Power Clutch). I Made a stupid move when I installed the clutch, I didn't replece the throw out or throw out fork...now I get to do an enging drop. =o(

I guess I will learn one day to spend the $$$ and do the "while I am in here" thing a little better.

oh the engine is a 1995 3.6 purchased here in Europe.

k9handler · 10-27-2005, 07:50 PM

Grady...question? Do you have a detailed list or way to install the new throw out bearing? When I installed the clutch, I had assistance from one of the mechanics at the garage help me...and he had a difficult time getting the rings in place and such. I would remember better had I done it myself!

Also the flywheel is only a couple years old, was installed with the 3.6 so I would hope it's in good enough shape to be refinished.

Grady Clay · 10-27-2005, 10:13 PM

K9,

That is one of the most difficult things for DIY – knowing what to replace on “General Principals.” The other is having ALL the parts at hand. A good shop has an inventory and ready access to all the common parts.

I’ll post the instructions in the morning (for me) for the bearing install.

I just thought of another potential place that could have failed – the bulkhead where the clutch cable Bowden tube seats. That takes very careful looking because when you release pressure a crack can close up and be almost invisible.

The only reason I brought up the flywheel is because of the time issue.

There is a major issue and recall for the engine wiring harness for ’95 & ’96. I only have the VIN numbers for the 10,300 USA & 455 Canada cars. You should check with a nearby Porsche dealer armed with your engine number. It shouldn’t be much effort for them to tell if it needs the harness or it has already been repaired.

Back to bed.

Best,
Grady

k9handler · 10-28-2005, 06:46 AM

Thanks Grady.

k9handler · 10-30-2005, 12:49 AM

question...just pulled the clutch cable and when the clutch stopped working the cable compressed the housing. My guess is buy a new clutch cable since the strength of the housing is compromised...do you agree? The cable I have is only 2 months old. =o(

HarryD · 10-30-2005, 01:14 AM

Quote:

Originally posted by k9handler
question...just pulled the clutch cable and when the clutch stopped working the cable compressed the housing. My guess is buy a new clutch cable since the strength of the housing is compromised...do you agree? The cable I have is only 2 months old. =o(

K9,

Sometimes it is just a simple thing: Zoom... Pop!!! Now what... can't get into gear!!!

Before you go into total panic mode, go slowly. Like stated above: Check the cable, check the pedal cluster and then check the tranny. My wrench told me the same thing when mine went south. All three of these things have very similar symptoms.

PorscheGuy79 · PorscheGuy79's Garage

Bummer, I just got through with dealing with the same issue.

k9handler · 10-30-2005, 02:05 AM

Harry...I have checked all of them and it's the clutch area (i.e. throw out bearing, fork, etc.) and at this point I won't know further until I drop the engine. I have been outside today getting everything ready, at this point all I have to do is trailer the car to the auto skills center where I can use a lift to perform the drop. I removed the fork assembly from an extra 915 I have on hand so now I need to price the other parts. May end up getting a new clutch as well just in case...would hate to get her all open and find the one in the car is worn down.