Found the Problem, Now What’s the Answer??

[OZCarrera3]

OK, I finally appear to have found the reason I cannot get my clutch adjustment correct.

When the clutch is depressed, the new clutch return spring that I have installed fouls the accelerator linkage shaft (refer to the photos below). This causes the accelerator to bind and changes the action of the spring causing the clutch to feel like it has two stages. It appears as if the windings of the spring are too long or the mounting stud is set too low (which is impossible, as its part of the pedal assembly.





I can’t for the life of me understand why this is happening. The spring can’t be mounted wrong, that’s the only way it can fit. I checked PET and there is only one spring (911 423 305 06) for the Carrera 3.0, which is the one I have. The 911S uses the spring 911 423 305 05. I have examples of both springs and the “05” spring is even bigger than the “06”.

This situation would only occur with right hand drive cars as the throttle linkage shaft crosses under the transmission tunnel from right to left. I assume that if a special spring was required for RHD cars then this would appear as an additional spring in PET.

Its all making sense now. I had assumed the old spring that I took off when I started this rebuild was a non-genuine spring customised to fit the car, as it had one of the winds on the spring straightened. I had thought this was to make it long enough, but in hindsight it must have been to clear the accelerator shaft. Unfotunately I relegated this part to the bin a long time ago. Lesson learned - don't throw anything away unilt the job is finished and everything is working as it should!

So what’s the story?? Have I done something really dumb? Does anyone (like John Walker) have any suggestions as to how I can fix this? Can I run the car without the helper spring (although I’d really prefer not to)?

[crustychief]

I can't answer your question, I will add a statement though.
Many 911 owners drive every day without a helper spring because they do not know it is broken. I hope someone familiar with the right hand drive version can help you out.

[john walker's workshop]

you don't have much choice at the moment, so take the spring off. like crusty mentioned, the system works without the spring. the pedal freeplay just won't be taken up to return the pedal fully to the stop.