New Clutch - and while I'm at it...

[ipaqrat]

The clutch in my '96 C4 coupe (@ 95K miles) a very heavy pedal and very short engagement at the top of the pedal. I bought it this way, and budgeted for clutch time. So I'm about to send it to get a new clutch and Dual Mass Fly Wheel. I believe I'll use OEM parts, if I can get them. Any overriding reason to use aftermarket?

Also on the list is the timing chain cover seal (detected in a prior inspection, but not a grevious problem).

While I'm at it, what ELSE should I get replaced, adjusted or inspected. Throw-out Bearing? Release Bearing? Chain tensioner? Plugs/Wires? I am spoiled by how smoothly and precisely my wife's RSX shifts; any recommendations on improving that?

Here are some other things that have happened or that I have observed:

-- The alternator belt burned off one day. Big puffs of black smoke blew in through the dash vents. Scared me so bad, I had the car trailered to the shop - the tow cost more than the belt job. No sign of anything specific that pushed it over the edge. Turns out what I thought was a transmission noise, was actually the belt slipping a little from time to time.

-- After revving up to @ 3000 or so (with the car sitting still in the driveway) I can hear a rattly, puffing sort or noise as the revs return to normal. Also the idle seems a little rough, sometimes enough to rock the body ever so slightly, just a little shudder. In a normal, pedestrian sort of car, I'd say it was a timing adjustment. What about with a Porsche?

-- Is there any way to get the retractable rear spoiler deployment to sound a little less like an old coffee grinder?

Thanks in advance for troubleshooting and brainstorming!

[Britwrench]

Hope this car has full service history, then you can see what has been done in the past and likely potential problems and maintenance requirements. Make sure you have the spare key and alarm remote and radio code.

When replacing the clutch, it's entirely possible the flywheel is ok. However, if your are going to keep the car, I would replace it.
The clutch kit comes with the release bearing. All the other components: pilot bearing, crank seal, flywheel bolts, release lever, shaft, both bearings and shaft seals should be replaced. The release bearing guide tube on the trans may be ok, replace the input shaft seal.
Use the Porsche clutch grease. Change the trans fluid.

When did it have the last service? If more than 15k miles ago will now need plugs, filters, distributor drive belt, possibly caps and rotors.

As it's a 96 and a Varioram, check and replace the air injection check valves if required.

Timing cover seals do leak, if you are doing all this work, and the leaks are more than "seepage" now is the time. Usually the gaskets between the cam chain housing and case seep too. Again, if doing one save money to do them both. Probably needs lower valve cover gaskets too. Check the power steering drive pulley seal on the cam shaft: easy to do now.

Before working on it, get a leakdown and compression test (if not done on the PPI) and a readout from PST2/Hammer tester and see what's going on.

The shredded belts syndrome is not new. Make sure the belt tension is both tight (tighter than normal belts, there is a Porsche tool to measure) and rechecked after 250 miles. The cooling fan belt warning light switch should be checked; they wear out.

Rear spoiler probably needs a good clean and lube, might need a lifting transmission. Try lube first.

At this mileage check the shocks. The wheel alignment is going to be done after engine in/out anyway.

[cowtown]

Originally posted by ipaqrat

-- Is there any way to get the retractable rear spoiler deployment to sound a little less like an old coffee grinder?

That's most likely the bearing in the spoiler transmission that Britwrench mentioned. I had success just changing out the bearing, and it's smooth and quiet now. There is a how-to procedure here:

http://p-car.com/diy/spoilerdrive/

[Don Plumley]

While it is out:

Replace SAI valve as a preventative. (If you pull the headers, look in the exhaust ports to visually check the SAI ports)
Replace the power steering belt
Replace the spark plugs
Clean the ISV

[ipaqrat]

Thanks for your insights! I'm about two weeks away from dropping the car off. I'm new to this, so I feel lucky that I can get wisdom instead of experience. As I get more of the latter, I'll look forward to passing it along here.