Guess the problem part 2
 

The second in the series of "test your troubleshooting skills"

Vehicle: 86 944
Mileage: 126000 miles
Clutch (spring centered), Pressure plate, TO bearing, master and slave replaced 15000 miles ago. Flywheel meets specification and was refaced at the time of clutch replacement

Car runs normally. Customer complains of clutch slipping at high RPM or at high torque. Smell of burnt clutch material.

No other noises, but customer states that the car just doesn't have the "oompf" it used to.

No further information

AFJuvat

Would a spring centered clutch make a burning smell???

Could the torque tube be loose??

944S Boyeee

Was just up till 2 am last night helping a friend with a ford probe gt replace his clutch. His symptoms were similar at first, but became worse. His Throw Out bearing was failing first, losing power at high RPM's and when he punched it off the line. When you would engage the clutch at low RPM's without giving it good revs, the engine would try to stall out. The next thing to start occuring was the sound of parts falling off, he was driving the car alil over a week before it was repaired. After getting the clutch out, the surface of the clutch material was ok, the TO bearing was GONE and several 'fingers on the pressure plate broke away. New clutch is in, along with a new flywheel... he's very happy.

Yeah....I bet he was happy (for once) he didn't have a 944, right?

I'm curious here, too.....my limited knowledge points to the clutch springs being too weak?? (just don't laugh, ok?)

Torque tube: No noise or vibration indicated

TO bearing: on the right track, but they usually make noise or vibrate when they start to fail.

Clutch Springs: Fine

Car is daily driver, not tracked. Owner does know how to drive a manual transmission vehicle properly - driving habits are not indicative of abuse.

AFJuvat

accidently replaced the 944 clutch disc with a 924 disc? hehe

Broken clutch fork not letting the TOB move "back" properly.

Or a cat got caught in the bell housing.

Small leak on the Slave Cylinder that's shooting oil on the disc. :D

I think you're on the right track.

My guess is leaking rear main. Moral: While you're in there, might as well do this...and this...oh, that too. :eek:

rear main seal

So many that are close, and yet so far away.

Hint: As I said before, Nothing is leaking

AFJuvat

Okay...if the clutch is SLIPPING then there's not sufficient friction on the clutch disc. Since you say there's nothing leaking, and the clutch was replaced recently, then something is adjusted incorrectly with the clutch fork/pressure plate which is allowing the disc to slip.

The pedal is not adjusted properly - too tight, not allowing clutch to release completely.

OK it's not a cat.

A possum?

they put the rings/clips on the throw out bearing wrong or came loose.....

BINGO

5 minute repair, 12mm wrench and a 9mm wrench, fixed.

AFJuvat

Where are the clutch pedal adjustments made at [just for future reference and my curiousity]? Thanks.

Who replaced the clutch and other items?

Guess thats why I am not a mechanic. I would have thought TO berring was not disengaging. It would have been partial right but by that time I have allready pulled the tranny.

Actually, I replaced the clutch.

Owner adjusted the cylinder for a "stiffer" pedal.

You make the adjustments at the clutch master cylinder - you screw the rod further in the pedal to loosen the pedal, and unscrew it to "tighten: it up.

Should have a couple of MM free play be design.

AFJuvat

You can adjust the "assist" spring to give you a "stiffer" pedal. In fact just take the darn thing out if you think you have strong legs.

Yes I said strong legs because it will take both of yours to push the pedal to the floor.

I'm leaving mine in but I sure wish I could get it to stop squeaking.

I hate this post because I can't get my psychic powers to work correctly.... I suck

Wait a second.. was he driving MY car?!?!!....