changing a 944 clutch solo, on jack stands...

[924s]

like the title says, i will be changing a 944 clutch myself with only the use of hand tools and four jack stands.

for those of you that dont know, book times for the job run between 18 and 22 hours.

i want to thank the loo crew for trying to help but unfortunatly we couldnt find a common free weekend.

if anyone in the des moines area is free this weekend (6-13-09) and wants to get their hands dirty, let me know.

[Jameson250s]

i woulda helped out, but i just got my appendix removed, sorry man.

[07GTI]

good luck Casey, I have relatives in town, otherwise I would have tried to help.

[OrangeDUB]

I'd be game if I didn't have a booked weekend! I've done a few clutches in my day- I'd be interested in how a Porsche one goes together! Good luck dude :beer:

[vwmeister]

I'd be game if I didn't have a booked weekend! I've done a few clutches in my day- I'd be interested in how a Porsche one goes together! Good luck dude :beer:


HAHAHAHAHA!!!!!!! That is too funny Casey!!! You need to experience doing a clutch on one. IMHO 944's are an engineering abortion.

Sorry we couldn't coordinate a time to get her done here. Nothing like antsy customers.

[Dubtuner]

I put a motor in either a 924 or 944 at the first shop i worked at and i did not enjoy it so i can imagine a clutch is a biotch

[924s]

thanks for the words of support.

kevin is right casey, doing a clutch on any other car is nothing like doing one on a 944.

here is my progress so far:
-no front plate ticket while picking up an 8mm and 12mm 12pt internal socket
-exhaust is on the floor
-shift linkage removed(one pipe from rear of car to shifter)
-transaxle on floor (had to lift it out)
-torque tube slid back 8in
-starter off
-speed and reference sensors out (i pray that engineer was fired)
-bell housing bolts out (probably the same puke as above)
-bell housing stuck on speed and reference sensor mount...
-arms are torn up from fiberglass insulation in tunnel

im working on the car again sunday but chances are it will be on jack stands untill i can get back up here next weekend (hopefully i remember how to put it together)

[924s]

-bell housing off (hell)
-clutch out
-flywheel off

progress will have to stop as i will be in alabama this week for work.

pictures of carnage will come soon

[Dubtuner]

nice progress

[924s]

nice progress

thanks
sorry for the cell phone pics...

work zone:
http://i280.photobucket.com/albums/kk177/thirdgenbird/SSPX0167.jpg

bum rubber clutch:
http://i280.photobucket.com/albums/kk177/thirdgenbird/SSPX0168.jpg

nearly sheared off "limp hone" tabs:
http://i280.photobucket.com/albums/kk177/thirdgenbird/SSPX0170.jpg

before anyone asks, the replacement clutch is a 951 style spring centered unit...

[924s]

-aluminum flywheel in
-clutch in
-starter in
-torque tube in
-tranny in

tomorrow
-half shafts
-shift linkage
-shifter
-shields
-exhaust

pray i didn't forget anything and turn the key...

[John2.0T]

Looks like you're making great progess!

Major props on tackling this on your own. Looking forward to meeting you and seeing your car!

[924s]

Looks like you're making great progess!

Major props on tackling this on your own. Looking forward to meeting you and seeing your car!

thanks

today:
-half shafts
-shift linkage
-shifter
-shields
-exhaust
-redline transmission fluid
-slave cylinder bled

then the moment came to start it, and all that resulted was an awful grinding noise. it sounded like a bum starter so i tried to push start it, more grinding... tested the started and it tested fine but sounded weak/dry... tried to push start it sans starter with no success but the grinding was gone. shimmed the starter with some washers and she started and sounded great for a few seconds then quit. tested the speed and reference sensors (same part number, one reads TDC off the flywheel and the other rotation speed off the ring gear) with a multimeter (its safe and possible) and they both read open between pin 1 and 3 (not good)

summary:
-clutch seems to work

-aluminum flywheel must be slightly thicker (a few thousandths) or the starter solenoid is not retracting all the way

-shimmed with washers till a solution is found

-speed and reference sensors must have been damaged during R&R

-i will be porscheless for euroworks...

[924s]

found another source that claims pins 1 and 3 SHOULD read open...

maybe i have another problem...