Wonderful clutch #*-$+#($*&&#-#($-#*@+!(

[84 944 oneowner]

Hello to all and hope all are staying safe if your in the path of weather. First, new master clutch and slave installed with new fluid and bleed with no bubbles. Fork does engage and i can see bearing moving as pedal is pumped. So what else could cause the clutch to not be able to engage? Any help is much appreciated.

[John_AZ]

Is the slave piston pushing the clutch fork all the way forward?

Press the clutch in and use a board to keep the pedal down (pressed against the seat).

Go under the car and look at the clutch inspection hole----how far has the slave piston moved the clutch fork?

The back of the clutch fork should almost be touching the bell housing.

In Clarks picture, the clutch fork is relaxed---if the pedal is pressed in it moves forward.

Checking Clutch Disc Wear

John

[84 944 oneowner]

Good point. Not it isnt. I kept bleeding thinking there was air still in the line but none found. It started to work for a moment then back to nothing like it is beling held back. But no the fork does not almost touch. It only goes just oast half way.

[John_AZ]

You probably have a pocket of air in the end of the slave.

When you bleed the slave, the front wheels are on the concrete, the rear is lifted to the top of a extended jackstand with a 2x4 under the frame.

What tool do you use to bleed with? Vacuum hand pump or Motive?

John

[84 944 oneowner]

I should add that the clutch disc should be ok. The car has never been driven hard or abused. It has 30kthe original miles. At 18kit i had porsche dealer put a new master and slave on it since it sat so long before. Since 1997i it only had 424milesto on it. All in one weekend. Then she was put back awa till now

[John_AZ]

Originally Posted by 84 944 oneowner

I should add that the clutch disc should be ok.

Sounds like a really nice car.

Mileage on the OEM rubber clutch disc means little. The rubber drys out and cracks.

Pull the starter and poke your finger in the bell housing. If you find any small pea size pieces of black rubber, the disc is failing.

John

[84 944 oneowner]

Thank you, i just love my car lol. I did have the starter out and checked for rubber fragments and the housing it was clean as a whistle. So i wonder if you are correct about a pocket of air. Thankyou for all the help over the last sevral months. I just do not trust alot of places to work on. Dings scratches etc. Not that people are not careful but just won't chance it.

[84 944 oneowner]

Sorry just noticed your last question. Yes front wheels on the ground rear all up. Tried with every method now. Even gravity which really sucked lol.

[John_AZ]

Years ago I owned early 924s-'77.5 & '79.
Took them to the best independent shops in town, Becks, Don Jackson, Tim Ransom ....

Not that they did not know the car, but they were more interested in the later year and more expensive Porsches or owners who had more money than time.

I just do it myself now.

Lift the rear high with an extended jackstand and rebleed the slave. Give it a try.

GL
John

[John_AZ]

Do you have the Motive power bleeder?
John

[84 944 oneowner]

Sounds like a good plan. I will put her back up in the air. And yes the rear is supported. By 6ton jacks that are fairly high. Enuff that i can work under it freely. I am smellin what ur steppin in. Thanks for the tips.

[oreke]

I made one of these to pressure flush/bleed the brake system:

The DIY $20 brake bleeder

and it worked really well.

On hindsight, considering the amount of time I spent collecting all the parts and building this thing, it would have been cheaper to just get a Motive Power Bleeder. I've seen them for around $50 online.

Bottom line: Pressure bleeders work well.

[84 944 oneowner]

So late today i plan on bleeding system again. Just wonder if anyone knows, is it possible to have the clutch plate stuck. "Rusted" so to speak. Just wondering. System worked fine and i rinsed engine bay then pulled car into garage.next day could not put into gear. That was last summer.

[zedsn]

I had a 240z years ago with a stuck clutch disc from sitting. I pulled the coil wire then depressed the clutch and used the starter to drive the car down the drivewayr till the disc unglued itself from the flywheel. Not saying this is your problem but this was my solution to mine.

[84 944 oneowner]

Thank you for the replies, i had some people look at me kinda crazy when i asked them about a clutch sticking. I knew it did not seem far fetched. After the honey do's hope to get back to the garage.

[84 944 oneowner]

So hope this pic shows up. After putting her back up, rebleeding i tried again. Still clutch will not engage when running! I did notice that tye right rear wheel was slightly moving and with that i could get it into 1s and 2ndi gear. But it really wasnt engaging properly. Any thought my good friends?

[84 944 oneowner]

Glad to report. The ride is fixed. Clutch plate was stuck. and after futher inspection the old master and slave are still good, good back up parts now lol. Nice to have peace of mind that all has been replaced though. Just wanted to say thank you all so much for the input.

[John_AZ]

Originally Posted by 84 944 oneowner

So hope this pic shows up. After putting her back up, rebleeding i tried again. Still clutch will not engage when running!

Any thought my good friends?

I thought your picture above was good and just about as far as a fork would travel,

I took a picture of my '88 (complete new Sachs set a couple of years ago) and the "GAP" of my fork/slave piston extended (rear) to the bell housing is 7.5mm (~3/8 inch)



I am glad you found the clutch sticking to be the problem.

If the problem returns and the bleeding is done correctly, I still think you should check the rubber hose from the slave to the hard line. This hose rots and swells under pressure when the clutch pedal is pressed.

A sticky clutch could be the TO Throw Out Guide tube cracked, the fork bearings crushed, or the OEM rubber disc binding the flywheel.

In any case, study clutch replacement DIYs--you are getting warning signs.....

John