marton

Hi,

The original problem was that the clutch pedal jammed down & started to vibrate like crazy. I cleared the jammed down by kicking the pedal after that the clutch worked more or less normally but with a big vibration. Garage took it apart and found one disc had completely lost its friction lining.

Now to the current problem. The new clutch won't release.
I went over to the garage to have a look - they
suspected that one of the new parts was wrong but the old clutch was
a Sachs too and we checked and all the part numbers matched up with the new one. They have replaced the 2 discs, intermediate disc, pressure plate, release and pilot bearings.
Probably good that I got a new intermediate plate, the old one had a
lot of blue marks and scratches.
They say that the release arm now does not line up correctly with the hole in the clutch cover but I did not see this as the clutch was out again when I got there. I got the impression that the end of the arm was too far away from the slave cylinder.
The garagiste is going to order a new arm to compare with the existing one.
I checked in the manual and there was a change of release arm but I
can not find out when, it also gives the impression that the new
release bearing will fit into the old arm OK but it is not clearly
stated.
The garagiste had called in a friend who also repairs 928s but he also could not see a problem.
Any ideas? Anybody had a similar problem. Could be the arm is bent but it is a pretty solid piece of metal, no obvious distortion. Also after the problem occured and after I got the pedal free then the clutch seemed to be moving in and out OK.

Marton 82s (built sept 81)

GlenL

Sounds to me like the shop just doesn't know what they are doing. Did they order the wrong kit? The arm doesn't just bend out of shape.

Maybe they aren't getting the upper ball stud on right. That can be checked from the top with the air box removed.

Also, go to www.nichols.nu and print out the instructions on how to bleed the clutch. It's not like doing the brakes.

marton

Hi Glenl,
Thanks for the reply, I agree with you about the arm.
The numbers on the new kit are the same as on the old clutch, for example, the pressure plate is a Sachs 200/215 so I guess the kit is OK?
Maybe right about the shop just doesn't know what they are doing but they seem to be following the book, they even have the little wire gadgets for slipping under the bolts to preload the clutch. The shop has 17 Porsches in work including 3 S4s.

Marton

GlenL

Marton,

All I can say is that it isn't making sense to me. The parts go together is a clear way. If they're the right parts, it should be straight-forward.

Thinking about it, I'll stick with the upper ball stud problem. It can be hard to get the plastic cup over the ball. Much easier if the cup is put on first, then the arm slipped over that.

jon928se

Marton

When you say won't release is it stuck or is the pedal not returning up to normal "foot off" position. If the latter tell them to check the brake fluid reservoir and probably top it up. Thenthe simplest way of nearly bleeding the clutch is to use a finger to push pushrod on the slave cylinder all the way in to the cylinder. This should get most of the air out.

Need to recheck the fluid afterward. Once this is done just putting foot on clutch pedal and pushing should reseat the ball cup.

Get it fixed quick ! not many weeks left until Beaulieu !

Jon
Black SE

marton

New release arm arrived yesterday for comparison purposes and it is a slightly different shape so it seems possible my arm is bent...
The new one would not fit because my car is fitted with the GTS arm 928 116 832 08.
Looks like in PET this arm also needs a different release bearing - anybody done this swap? I have a 928.116.085.24 and I saw in in PET that the GTS has a release bearing with a number finishing in 08.
New GTS release arm should arrive today so maybe the shop can move forward.

Marton
Long time since I was in Minneapolis, it was when I worked for Honeywell and it was late December. Talk about a white Christmas, snow must have been 3 foot deep.

GlenL

Now I'm really confused. A GTS arm with a '82 clutch? Don't know if it works or not. If the correct arm was available, then I'd suggest using one of those.

Old & New

Marton,

I can tell you that there are different bearings for different arms, as I just ran into that when I did a dual disk retrograde conversion in my 89. If the arm has a convex spot, you need the bearing with a flat surface. If the arm has a flat surface, you need the bearing with a convex spot.

marton

Thanks guys, I have done about 30K Km since I bought the car so I guess the GTS arm must work OK with the dual disc clutch. Maybe they had to modify something else but I have no clue what they might have done

Marton

marton

Thanks guys, I have done about 30K Km since I bought the car so I guess the GTS arm must work OK with the dual disc clutch. Maybe they had to modify something else but I have no clue what they might have done

Marton
Forgot to add, God bless the previous owner

marton

Got my 928 back from the shop today complete with a new and unbent GTS clutch release arm. Feels very good to drive, better than it ever did. Still a bit crunchy to go into second but I can live with that.

Pricewise, the garagiste will stick to his original price quote plus the price of the new arm - so I am happy with that.

thanks again guys

Marton
brm... brm.....