the flyin' scotsman

thx Hilton..........Im replacing the pressure plate with new which came direct from Porsche with no spacers installed.

Perhaps I need bigger C-clamps?

Bilal928S4

Malcolm,
As per the write up I sent you and my recollection, if you assemble everything together and kneel on the assembly on the floor you should be able to put the shims in. At least that is what my faint memory remembers.

the flyin' scotsman

indeed Bilal, the write ups do show a pic of someone kneeling on the PP but that's to install the throw out brg assembly........I looked at that write up/pic and the shims are in place.

Wisconsin Joe

There's a lot of force in those springs. They are what holds the clutch plates together.

It's going to take a fairly "hefty" person on top of it to compress them.

I'm only experienced on the earlier dual disk clutches, but on those the shims are "optional". You can simply back the bolts out a turn at a time to relieve the preload, then take them out. I would think you could reverse that if needed. As in put the PP in, thread the bolts into the flywheel to contact, then tighten them a turn at a time to get the preload in. Then you'd be able to put the shims in and take it back out to do whatever else needs to be done.

And, of course, this may not work on the single disk setups.

WSM, section 2, page 30-15 or so.

the flyin' scotsman

thx Joe...........I was thinking exact same as I have the flywheel off the car

the flyin' scotsman

I bolted the new PP to the flywheel and compressed the springs so I can install the brackets; see attached

GlennD

So I am confused. If you can bolt the clutch assembly to the flywheel when off the car without shims, why can you not do it when the flywheel is on the car? Just need to rotate the engine a few more times to ensure the bolts are started and torqued evenly.

I was trying to use shims when I did mine and a couple fell out when I was wrestling the clutch pack out. Gave up using the shims and just bolted the pack in (after replacing all the bearings, etc.) just like you did as per your picture.

What did I miss?

Thanks
Glenn

the flyin' scotsman

to use the 'old' clutch lever with the new TO brg and new PP the PP has to be compressed to a degree and using the shims permits this. As my new PP came without shims the easiest and what has proven to be safest method is to bolt it to the flywheel. This allows the shims to be installed then the lever and TO brg can be installed.

I would think your clutch pack came all assembled (PP, TO brg, lever, plate) Glenn?

worf928

Malcolm, your '92 GTS may not have a 'GTS' release arm and thus your old arm may not work with the new T/O bearing. Examine your arm thoroughly against pictures of the old and new arms.

I did a clutch on an early-93 (so, really a '92) a while ago and was shocked to discover all 'pre-GTS' parts. While it is possible to install an old release arm onto a new bearing, you'll know it's all wrong because once you relieve the pressure on the PP, the arm won't move. You do not want to discover this after the assembly is bolted to the flywheel.

Last, the shims make it much easier (as in possible in some cases) to get the clutch assembly into the housing with a nice new clutch disc.

the flyin' scotsman

thx Dave.....I was aware of the clutch changes for the GTS and wrongly believed all would be same.

My car is an odd ball in that many parts are date stamped 1991 as it was built then sold in early 1992. Given the only immediate previous 5 speed model was the GT its possible Porsche were doing their 'use up of old parts' trick as we've verified with other models.

the flyin' scotsman

I verified the release arm is stamped 928 118 832 07 which is the older version.

Is there a tech bulletin that describes which release arm to use with the new TO brg? The new TO brg I have is part 928 116 085 08

Looks as Im dipping into the parts funds again.

GlennD

Malcolm,

Thanks for the reply. Mine was not an assembly but rather a box of parts. New TO bearing, new pilot bearing, etc. all which I installed - similar to what you are doing.
I tried to use the brackets but after they fell out when removing the assembly, I just proceeded without them. No issues. Humm, now I wonder if it would have been easier had I used them. As it was, the largest challenge was removal of the pilot bearing as my puller was too big (used bread and grease technique - worked fine, just took a few minutes).
Cheers
Glenn

the flyin' scotsman

no worries Glenn..........did you re-use the release arm and pressure plate? if so, did you have issues assembling without the shims being in place?

GlennD

Malcolm,

New arm, reused pressure plate (with new parts). Had the flywheel resurfaced (it was in excellent shape and did not need anything taken off according to the machinist).

I had no issues putting it back together without the shims. But as I stated, it may have been easier with the shims but I am not sure how.

Good luck with your job. It will be an amazing piece of work you are doing again given all the new parts and care you always take

Glenn

the flyin' scotsman

thx Glenn.

Does anyone understand the differences between the older and newer clutch release arms? Can the old arm be modified to use with the new TO brg?