gomez123

I just finished installing a new clutch assembly in my garage using a lift on a 82 928. I have a full service garage with a BendPak lift. Doing this job for the first time it was no joy I can tell you. I work mostly on 911's here but I decided to buy a 928 and give it a go.Need's lot's of work but I'm enjoying the learning curve. Since this is my first clutch job on a 928 I'm sure the next one will go smoother. God my arms and neck are killing me.

hacker-pschorr

First time I dropped the assembly on my head, thankfully it wasn't that far off the ground. The marks on my forehead from the starter gear didn't go away for a long time.

Now it's second nature to pull the assembly down with my head out of the way and my chest below, better angle anyway to keep it from hitting me.


On that note, I have a new garage rule:
Never work under the car after midnight, I feel asleep while doing rod bearings. I woke up covered in oil and sat straight up. Counterweights on crankshafts are very, very hard.

SeanR

I much prefer to do them on the floor over doing them on the lift. For me, much better leverage and not as far for it to fall when it does.

docmirror

Yup, I took a face full of clutch/PP about 5 years ago. The scars heal, and I'm once again the ugly troll of my youth. The 928 is a lot of things, but one thing it surely is not - another 911.

Guy

I have done the job four times now on the floor in my garage. Every time I go to install it seems like the first time in regards to body positioning etc. I am hoping it was my last.......

gomez123

The older I get the more claustrophobic I get. I could never lay under a car for that long. Reminds me of a MRI machine. I got cuts and sore arms but no smashed teeth. I thought the 928 with the access at the bell housing would be a breeze NOT. Not enough room to move the stuff around. The next time will be easier. The darn pins were frozen in the intermediate plate couldn't budge them so the clutch assy. wouldn't move reward enough to remove it so I had to cut them off with a cut off wheel and replace them with tensioning pins on reassembly. Will finish tomorrow having some trepidation with the adjustment of the intermediate plate. I loaded the TO brg arm with a ratchet strap and turned the output shaft and there doesn't seem to be much drag just slight contact. Now preying no judder PLEASE!!!

Bigfoot928

I had to do a double disk clutch on the side of the road. I spent about 20 minutes brushing away all the little rocks on the asphalt......then it got real....

Dave928S

Real men do it on the floor

Adk46

Hey, Gomez123 - I just noticed you are in Saratoga. Have we met at a PCA function? (Will you be coming to Camp 928 next year in Chestertown? You can bring your '82 SC if you don't have your 928 running yet.)

gomez123

Sounds good to me. I'm a PCA member.

Wisconsin Joe

^This.

I didn't even have liftbars at that point, so it was just up on stands.

While there were issues, it was by far the easiest clutch job I've ever done or seen.

I had a "challenging" time getting the short shaft out of the pilot bearing, but once past that, sailed right through.

I had a helper for the install. Having a second pair of hands made a huge difference. We both lifted it up, one held it and the other slid the short shaft into place.

In the "kinda funny, but go figure" dept, the whole thing went up, and the short shaft slid right in. Then I realized that I forgot to lube the ball cup for the release lever. Drop it back down, lube the ball cup, and then spend about 15 minutes and maybe three or four tries to get the short shaft into place.

Didn't even drop it on my head. I had read the warnings about that.

hacker-pschorr

How about off the back of a trailer in a field?

https://rennlist.com/forums/928-foru...d-america.html

Ad0911

Any hacks or tricks on putting it back together again? Tools that make it easier or safer?

davek9

Install the three "U" Clips for the pressure plate BEFORE unbolting it

dr bob

^^^^ Absolutely Essential ^^^^ Without this, it's more than a chore getting things in and out, and getting the disc centered again unless you have three hands.

Anf FWIW, I believe it's easier with the car up just a foot or two vs lifting the whole clutch pack over your head under a full-height lift.