So is it my clutch or the hydraulics

[desertsoldier22]

Over the past few weeks the effort necessary to press my clutch pedal has steadily decreased. Yesterday morning I pressed the clutch pedal and it took no effort at all and the pedal somewhat hesitated when it was released, almost like it got stuck on something as it was coming back up. Sensing a possible slave/master cylinder issue I put the car on ramps and started checking for leaks, none were foound on either the master or the slave cylinder. I also bled the system and yes I found air bubbles. I bled the thing for almost two hours util pretty much the whole system had new fluid. I capped her off, and drove her again but to no avail she still feels like pushing into nothingness when the clutch is pressed and she has a noticeable pop when when the pedal is released. Frighteningly when I revved her passed 4000 rpms with the pedal released in first gear she slipped, I pressed the clutch pedal again and released and she stopped slipping. Its almost like the clutch is only partially engaged when the pedal is fully released and I am afraid this is like holding your foot on the clutch pedal she will eventually wipe her disc out.

[Wayne 962]

What your describing sounds like a clutch that is wearing out. Of course, it might be a slave or master that is leaking internally, but I believe that to not be very common. I would probably plan on replacing the clutch, and I would also replace the slave at the same time.

Or, you can simply replace the slave first and see if it fixes the problem. Come to think of it, if it were my car, I would probably do that first.

Here are two articles to assist:
Pelican Technical Article: Boxster Clutch Replacement - 986 / 987

Pelican Technical Article: Boxster Clutch Hydraulics Overhaul (Boxster Master Cylinder & Boxster Slave Cylinder Replacement) - 986 / 987

-Wayne

[desertsoldier22]

Hopefully it is one of the cylinders, otherwise it means me wasting a weekend improving my upper body strength.

I have a Bentley manual and your Porsche projects book, it seems pretty straightforward.

[desertsoldier22]

When replacing the clutch, can I use any 987 components for added strength? Or are they not compatible?

[tomk]

I agree with Wayne's recommendation and I had the same symptoms, however, in my own case the clutch arm was failing, and ultimately broke causing the slave to over extend and ruining the slave. Once I got it apart I did the usual, RMS, IMS, clutch, slave and a new arm and several small pieces. Moral, dont delay too much or you might have to replace the slave as well, and the only way to find out for sure involves improving your upper body strength, good luck

[desertsoldier22]

Well I ordered a new slave and main cylinder, but I noticed something weird this morning. My clutch started feeling normal again, then when it warmed up later in the morning it started acting funky again. I have a hopeful feeling that it is the hydraulics and the thicker colder fluid is allowing the cylinders to work properly, but when it warms up I think the fluid is getting past the internal diaphram.

[desertsoldier22]

In any case I have a clutch and flywheel ready to go...would'nt mind getting the rest of the super clutch kit components though. My IMS was replaced 4,000 miles ago at the dealer under warranty and the clutch components looked fine, but I hope the potential hydraulics issue didn't damage the pressure plate and disc too much.

[tomk]

if fluid were getting past the diaphram for the master you would have fluid inside the car near the clutch. if fluid was getting past the slave you would see fluid coming out of the small opening at the bottom of the bellhosing. Is the resovoir dropping?

[Alphaboy1]

desertsoldier22... Just curious. How did you manage dealer to replace IMS under warranty?

[desertsoldier22]

I purchased a 100,000 mile extended warranty that covers everything except wearable items
(Clutch, pads,etc)
Would not have bought the car without it

[Alphaboy1]

Was that from another company or direct from Porsche?

[59coupe]

+1 on Waynes' diagnosis. Replace clutch. And all of the other stuff while you are there.

[BYprodriver]

Originally Posted by Alphaboy1

desertsoldier22... Just curious. How did you manage dealer to replace IMS under warranty?

I'll bet it was the IMS flange cover only?

[desertsoldier22]

Nope...they ordered Pelican's whole bearing kit and they installed it. They said (Porsche) either the Pelican improved bearing kit or LN engineering's ceramic kit was the best way to go, they also said the oem part was garbage. When I took it in to get a certified inspection they found a "cam deviance" and gave me my options. The old bearing was pretty close to gone, which is a shame because if the engine took a crap, my warranty would have replaced the whole engine and they give me a choice of who to get the engine from as long as it does not exceed the factory price of the engine. That could have been fun

The warranty is through another company called Capital Finance Group. I have the gold warranty which covers everything except wearable items with a $100 deductable

[desertsoldier22]

To get back on topic, I replace the primary and slave cylinder's yesterday. Well my pedal feel is better, better to the extent that now I can feel exactly what is going on with the clutch. My pressure plate springs are shot to hell. Its keeping the friction disc from fully engaging the flywheel surface, which is why sometimes I get slippage, press the pedal again and release and it will stop slipping. The disc is close to dying, it will slip at 4000+rpms, so I am driving like a grandma until I can get her on a lift next weekend. Already have a good flywheel from a 2004 Boxster S with 18,000 miles, and a new 987S Sachs clutch kit. I am going to order all the bolts, grease, TOB arm,clip, bearing tube, tranny input seal and pilot bearing tomorrow. I even have a spare new axle for the Passenger side. I have been preparing for this eventuality for a couple months now.

[desertsoldier22]

I do have a question about the Cayman Clutch though...it has this small silver cylindrical piece with it, its not the TOB. I don't think the Boxster has this part. Otherwise it looks just like a Boxster clutch from the pictures in the Bentley manual.

[tomk]

sounds like the pilot bearing?

[desertsoldier22]

Yep your right it comes with one...nice.
The clutch is actually cheaper than an 03 Boxster clutch too. Weird pricing on Porsche parts...they are all over the place

[desertsoldier22]

Pulled ythe tranny this weekend and the clutch disc fell apart in my hands lol! Suprising enough the flywheel looks good. This is fortunate because the one I bought looked like it was scraped on asphalt and was unservicable. Unfortunately some knucklehead sent me a 5 speed clutch kit instead of a 6 speed. (In a six speed box)Since *********.com has never heard of an invention called the telephone, and they wanted me to pay to ship it back. I bought a clutch from Autozone...it is Sachs branded as Duralast. So Wedensday I should beup and running
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Any body want a cheap 5 speed clutch...