Clutch Job Help

[lousailor]

Well I've been forced to tackle this now. I think the rubber center went long ago, but the clutch is now starting to slip under acceleration and it's only a matter of time before a total No-Go. Sooo...Car is up, exhaust removed, trans is disconnected, starter is gone, and slave cyl moved to the side. I cannot break loose the two upper center tube to clutch housing bolts. Does anyone have a good tip? Also after those I've got to get the upper clutch housing bolts which will be a bear as well. What's the best tool/technique to use? I can't seem to get much leverage on the TT bolts, and I can't even see the upper housing bolts. Do I need to get at those from the engine bay? Thanks a bunch

[ae1969]

- the top bellhousing bolts you will need to get at them from the top...
- you will have to rig a longer extension to get leverage... the top 2 TT bolts attaching to the bell housing can be a pain to get at....
- before you release the top two tranny housing mounting bolts.... hit them with a hammer... wake them up.... make sure you have a GOOD allen socket as well....... They do come off fairly easy and you have enough room to get a long rachet to get more leverage. BUT before you loosen these bolts.... loosen the tranny to torque tube coupler FIRST.... and slide it off to one side.

Have fun.....

[SoCal Driver]

Did you say the trans is disconnected AND removed? Trans has to be out of the car.

[lousailor]

SoCal,
I was wondering about that. Right now it's lowered and moved back, but I haven't disconnected the axles. Will I need to move the TT that far back to disengage it? Thanks

[Taz's Master]

Yes, the tranny must come out (its mounting bracket also). Try 2 combination wrenches to break loose the 2 TT bolts (the box end over the bolt, and the other wrench's box end over one part of the open end).

Are you using Clrak's Garage for help? You really should check out his site if you haven't.

[lousailor]

Hmmm,
I'm not sure I understand the two wrench thing. I've got both the print out from Clark's as well as my Haynes, and pics from PET. All I've got left on the trans is the axle bolts. From what I can tell the hardest thing is breaking loose the TT from the clutch housing and unbolting the clutch housing from the motor. The rest looks easy enough.

[Taz's Master]

2 combination wrenches: Take your 17mm and put the box end over the bolt head. Then hook your 18mm's box end over one of arms of the open end so that the outside of the box is over the outside of the arm, and the shaft of the wrench is between the arms, should effectively double the length (and therefore the torque) of your wrench.

[lousailor]

Aaahh Haah!

[tank]

hi noob here, be careful of the crank sensor on the left rear of the engine/bellhousing.how much did you pay for your clutch?

[SoCal Driver]

Good call tank! Remove the sensors or you will add another $150 to the repair bill.

[robthe54]

if it doesn't have it, cut a notch in the bell housing, so you don't have to take those crank sensors off next time...

[lousailor]

Hmm Rob,
You mean notch the housing so the sensors don't impede it's removal? I got the sensors out. easier when you can reach in from above (had to lower the car). Removed the TT bolts and then the cat heat sheild so I could slide it back. Now I'm going to attack the upper housing bolts (they sure are inciniently placed). I tell you things start to make sense when you've got all these pieces out of the car.

[ae1969]

Originally posted by lousailor
..............I tell you things start to make sense when you've got all these pieces out of the car.

What will really freak you out .... is when you put it all back together and noticed all the extra bolts and pieces porsche threw in that you can't find a home for....

[tank]

i have to admit the clutch job in a 944 is intimidating the first time, even for a 15 year auto tech like myself. goes smooth though.

if you keep your work space clean, tools neatly on a cart, keep all parts out of your way, out of immed. sight is better yet, and things of that nature you will be alot more at ease and not stressing yourself out fighting everything. that is if you get like that.

[lousailor]

Well I'm down to two stubborn pieces. The left lower clutch housing bolt which is tucked way up between the housing and the firewall. Tried using my socket with a wobble extension and a pipe of the handle, but it won't budge. I could put a little more torque on it if I could make more handle room, but the angle brings my knuckles back into the housing. And then there's the clutch fork shaft. Even squirted some PB Blaster in the retaining bolt hole, but all the prying and tapping with a hammer won't move it as well. I think I've got a way to rig a psuedo gear puller that may move it. Let ya all know tomorrow.

[Taz's Master]

I ran the bolt through a socket with a nut and washer on the threads and tightened down on the socket to pull the pivot shaft from the housing.

[bryanthompson]

Are you taking any pictures? I'll be doing my clutch during the summertime, and am pretty intimidated. I've got all the manuals, but more pictures are always helpful

Good luck with the project. How's the difficulty rank with anything else you've done with the car?

[ae1969]

I attach a bolt on the pivot shaft........ attach a visegrip and attach a 10lb slide hammer to that......... and hammer away.

Its the only way I have ever been able to move that shaft.

The haynes manuals method is quite amuzing as I recall.....something about using a screwdriver and lightly prying at it....

The shaft is usually seized on. Enjoy this one...

[robthe54]

i'm with ae1969. just make sure that lock bolt is out.

[SoCal Driver]

If you can't get the cross shaft out just unbolt the pressure plate from the flywheel. Nine bolts. The whole thing will drop out where you can get a better angle on it.