Ad0911

I am at the point of decision making whether or not I should get a new intermediate shaft. As you can see from the picture, the cluthc-side is pretty worn out. I don't remember that it made any noise but the mechanic in me says that there is too much play in the spines. Should I?

Rob Edwards

Yeah, that's pretty bad- was there any notchy feeling in the clutch pedal? I think the hassle with wear on the intermediate shaft is that the clutch doesn't disengage cleanly, which can't be good for the synchros over time.. Probably cheaper to get a good used one from 928Intl - $100 for another 2 days...

http://shop.site-link.com/928intl/pr...928-421-235-16

Dave928S

That's definitely beyond what's serviceable. The ridge causes the driven plates to settle in a set position (particularly the front one), instead of floating and finding a natural released position on the shaft.

For comparison, here's a pic of one that's still serviceable, but the line shows where the stepping is only just starting to show.

Mrmerlin

yep the shaft is worn beyond serviceable.
and its a safe bet so are the clutch disc hubs.

Greg Brown has new uber shafts, and clutch discs,
hurry might get yourself an early Christmas present.

NOTE use the special Porsche grease for the splines.

NOTE this wear results from corrosion/ moisture, see the rusty looking staining

Ad0911

I sure hope that the clutch discs do not have such excessive wearing because they are reconditioned by the dealer after they broke off a piece of the friction material during a demonstration at 928 club event

Mrmerlin

ADO the only way to tell is to have a new clutch disc and your used one, and fresh stub shaft,
if the spline play is minimal on both discs then they should be OK .

otherwise the worn hubs will have more play that the new versions and wear out the new stub shaft quicker

EMan 928

Hi Stan, what special porsche grease are you referring to? And, Merry Christmas!

James Bailey

If reconditioned means rebuilt then they would have simply replaced the friction surfaces and done nothing to the hubs..... it is however less critical if the hubs are worn since they do not develop a step like the shaft will.

Mrmerlin

though with worn splines on the disc hub they might not grab evenly on the new stub shaft,
and thus uneven wear will result

The grease is in the PET for the clutch assembly

Ad0911

Well, MrMerlin is always right! I noticed some wear on the splines of one of the discs. This must be the front disc. See pictures. Can I use a good used clutch disc or buy a new one?
First and third picture ar the same disc (the "bad" one).
Second and fourth picture the other disc (the "better"one)

Dave928S

I hate to give you the bad news, but both those hub splines are shot. If you use those on a new shaft they'll have rotational slop because of the already worn splines, and will hammer the splines on the new shaft. Those hubs wouldn't have been doing much sliding on the shaft in that condition, and so I'd guess that you clutch release hasn't been too good lately.

You need a new stub shaft and new driven plates.

Roger has tubes of the right extreme pressure high temp grease.

Ad0911

Thanks, I already discussed this with Tom at 928Intl. He was very patient with me for which I am very grateful!

Dave928S

I would think that 928Intl would also have the grease, which also comes in a little sachet when you buy a complete clutch kit.

Mrmerlin

yep those disc hubs are toast.

NOTE liberal use of the special grease will prolong the spline health,
NOTE spread the grease with an old tooth brush onto the hubs and the shaft splines and the pilot bearing.

NOTE when fitting the clutch back together, Test fit the new stub shaft and install the guide tube to the housing ,

NOTE then put a mark on the shaft where it comes out the back of the guide tube after pushing the stub shaft into the pilot bearing then pulling it out about 3 MM,
this will center the stub shaft pilot bearing surface and prevent the the shaft from bottoming out on the back of the pilot bearing.


Once you have the mark made you can install the clutch pack then simply slide the stub shaft to your mark then fit the coupler then tighten the pinch bolts.

17prospective buyer

Wow! Those are done.