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Old 09-05-2011, 01:35 AM   #1
happyfelthappy
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Join Date: Aug 2011
Location: Hayward, CA
Posts: 20
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Talking DIY Clutch Replacement PICS '83 Porsche 944 NA

This is a repost from the 944 Tech. forum, I am not sure if it is better to post it here or leave it there.

Hello everybody,

Warning: This is my first post on Rennlist. I really like how useful the info on this site is. This is more of a supplement to the WSM and the various writeups that are mentioned below. I did not writeup step by step what to do since there are other posts online that do a great job of that.

A bit about me: I am a newbie to the world of Porsche. I am a twenty year old guy living in the SF Bay area. I have owned a couple of cars in the last couple of years, the first being a '95 240SX, then a '91 Camaro RS, lately I have had a '99 BMW E46, a E36 BMW 328i, and just bought a '83 Porsche 944 a couple of weeks ago.

Soon after driving the car, I realized the clutch seemed to have problems. The whole car would shake when I pushed the gas or let off the gas pedal. Felt like I was on a seesaw. Some research indicated that the rubber center on my clutch has most likely sheared and the "stops" which are like a limp mode for the clutch were getting brutally abused. I tried letting off of the clutch and playing with the gas for about a week but I soon started looking for a clutch kit.

Parts List:
Pilot bearing
Sachs Spring Centered Clutch Kit w/ release bearing & pressure plate
9 Flywheel bolts
Front Transmission shaft seal
Rear Main Seal
Needle Bearings for Clutch Fork
Swepco 201 Transmission Fluid
Clutch Alignment tool is Ford #03 I believe it is used in various Ford Clutch Kits. The Sachs kit did not include this but a friend from the local Pep Boys Parts counter let me borrow one.

I bought all of the seals from Parts Heaven a local Porsche used and new Parts place.
I luckily found a upgraded Sachs Spring Clutch kit on Ebay for about $460.

Tools:
10 MM Cheesehead (Triple Square) for the half shafts
19 MM Wrenches
Metric Socket Set: 8 MM to 19 MM
Metric Wrench Set: 8 MM to 19 MM (Ratcheting Set is a plus)
Standard Socket set sometimes comes in handy
1/2 inch socket for triple square bits
3/8 inch ratchet
1/2 inch ratchet
3/8 inch extensions of various lengths
3/4 inch ratchet
Various Pry Bars
3/8 Breaker Bar
Torque Wrench


Tips:
-Remove battery connections.
-Get a good set of Triple square. I did not want to strip my bolt heads so I placed the bit into the head and hit it with a block of wood before using the ratchet on them.
-Cover Half Shafts with plastic baggies
-Clean Transmission while it is out (I should have)
-Use Pry bar gently pushing coupling towards transmission away from engine and driveshaft.
-Put block or something to hold clutch pedal down in order to move shaft spline. Shaft will not move even with parking brake off and transmission in Neutral!
-Make room above clutch housing bolts in the engine bay in order to remove top bolt without breaking anything. (I damaged a plug in the back of engine bay)

I used many sources to read up on this before starting the clutch job. Many thanks to Rennlist and these sites here:
These writeups are much more thorough than mine is however do not have pictures.

http://forums.rennlist.com/rennforum...ml#post6847868

http://connact.com/~kgross/FAQ/944faqcu.html
Torque Specs here^
http://www.mikepellegrini.com/porsche_manual.php

http://www-public.tu-bs.de:8080/~y00...944clutch.html
Torque Specs are here also^

http://www.clarks-garage.com/pdf-manual/clutch-01.pdf

http://www.mademan.com/mm/how-change...rsche-944.html

Now for some pics and various comments: This is my first time trying to post pics and sort of a DIY on here, so sorry for the errors I will make =]


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A Lift and transmission jacks make this job a bit easier.
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It was kind of difficult to seperate this coupling. I read over the tip for putting a block of wood to hold down clutch pedal in order to turn shaft and open bolts on the coupling easily.
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The Spring Clutch looks pretty nice.
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Good Luck, please make improvements or add anything that I may have missed. I will add it to the original post!
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Old 09-05-2011, 01:35 AM
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