Measuring clutch wear

montauk · 12-28-2003, 08:27 PM

I had the clutch replaced on my 944 s2 cab last week - ouch! It wasn't cheap. The clutch plate was okay but the rubber disk had let loose. Driving it home from the mechanic's shop, it felt like the slave cylinder was weak. I replaced the clutch master and the slave on Saturday. Pedal feel is much stronger.

Anyway, when I was under there I noticed that the release lever distance is where it would be for a worn out clutch, not a new one. The repair manual has a diagram showing how to measure the wear on the plate. The book says 18mm for a new clutch and 34mm for a worn out one. The mechanic installed a clutch for a turbo. The turbo manual lists the same dimensions. Is there any way this could be correct? I'm going to call the mechanic tomorrow. I hope he has a reasonable explanation.

Thanks
Dave

montauk · 12-29-2003, 04:27 AM

One more thing, when I took off the old slave cylinder, the arm could swing freely for about a half an inch.
Dave

SoCal Driver · SoCal Driver's Garage

You would think the mech should have caught any cylinder problems with the clutch repair. If he took off the slave cylinder there may have been air in the system from bleeding -- spongy. If that was the case then the cylinders did not need replacing. Just needed to bleed the system proper.

The TO bearing arm will do that. No prob there. Just adjust it back to factory.

You need to have the pedal free play at 1/8".

montauk · 12-29-2003, 06:51 AM

Thanks. My mistake on the measurement. I read it backwards! I used a caliper to be sure. It's just over 18mm.

This mechanic is excellent. My previous mechanic that did the belts told me that the vibration I felt was normal. Not knowing any better, I took his word for it. This mechanic noticed the vibration and fixed it. The other guy had put the balance shaft in 180 degrees out. What a difference!!

Dave