Jaggi

I had the clutch, the flywheel and the clutch slave cylinder on the transmission of my 1991 964 C4 replaced.
At the beginning the clutch pedal was stuck in a very low position and only after using a power bleeder we were able to get the pedal back into a normal operating position.
Unfortunately the clutch is still not fully opening and I can barely get into any gear despite pushing the clutch pedal as much down to the floorboard as I can. It seems I need another 1/2 inch more pedal travel to release the clutch.
Any idea what I can do to correct the problem? Do I have to use a power bleeder and the hammer tool together to bleed the clutch hydraulic? I own the Durametric software but somehow the brake module is not working on my car.
Does anybody have a simple procedure how to bleed the C4 clutch hydraulics and any good ideas what I can do to increase the travel of my clutch pedal?

Thanks

Indycam

If you pump the pedal , can you get it into gear ok ?

Rocket Rob

Clutch problems should be addressed in order of easiest/lowest cost progressing to more expensive/invasive. You should first check to see if your clutch pedal stop is set correctly. Assuming it is, then you need to try the following.

1) Bleed the clutch. If that doesn't resolve it, go to #2
2) Replace the slave cylinder & hydraulic line. If that doesn't resolve it, go to #3
3) Replace the master cylinder. If that doesn't resolve it, go to #4
4) Check the clutch pedal roll pin.

Last resort, replace clutch

Good luck on the repair.

tbennett017

Second the ^^^ and don't be afraid to bleed the clutch slave. Its easy with the PowerBleeder. That really sounds like your problem to me. Just dont' forget to block off the reservoir vent hose first, otherwise you will get brake fluid all over the place...

DAVISRILEY

I don't know anyone that has ever done this. Should have seen me the first time I flushed the brakes, put 2 pints on the ground before I cought it.

I concur with the bleeding first. You would be amazed the muck that comes out of them.

raymond-turner

Roll pin, do a search, had the same problem recently, good luck

gchristofi

shouldn't pedal roll pin be 2nd, if not 1st on the list?

Rocket Rob

The roll pin could be moved to #2, ahead of the slave & master cylinders. I still feel that bleeding the clutch would be #1.

Jaggi

Thanks for the feedback. I have bled the clutch hydraulic 2 times with a power bleeder and don't think there is any air in the system. Do I need to start the pressure pump of the car to bleed the system (I have a C4) or can I just do it with a pressure bleeder on the reservoir?
Any directions how I have to bleed the clutch properly and do I need to bleed it together with the brakes and the hydraulic locks?

Jaggi

Just one additional clarification. I cannot/or at least barely get the car into gear with the engine running. Pumping the pedal is not helping either. What I typically do is to put the car in gear and the press the clutch and start the car. It is very obvious that the clutch is not opening properly as you can feel the car moving a little when I use the electric starter.

Indycam

So if the motor is running and you pump the pedal 10 times ,
you can't get it into gear ?

Bluey964

Sounds to me like the slave cylinder - also replace the hose there as well when you do it. I had difficulty in getting mine into first gear when running and was that. One tell tale is if you have a load of black gunk come out when you'd bled the slave originally - good indication of the failing part.

Jaggi

I had the clutch slave cylinder changed with the clutch. Are there different versions and might I have the wrong one installed? There is no air in the hydraulic system ( I bled it 5 times) and it is not changing the clutch behavior when I pump the pedal 10 times. I will check the roll pin on the weekend but are there other things I should verify?
Thanks

dfinnegan

I've not done a clutch, so I don't know the mechanics, but are you sure the new clutch was installed correctly?

Were you able to drive the car at all after the new clutch went in?

Colin 90 C2

sounds like a binding pressure plate. or possibly a broken spring finger that is lodged into the pressure plate and not letting it release.

I have not had this problem in a Porsche, but it has happened to me twice before, once in a Toyota truck and once in a VW Passat. I drove the VW home from vacation. A 140 mile drive in traffic, with no clutch.
You learn to double clutch real quick.

I can not believe that this would happen with a new clutch though.

For your sake, I hope one of the other suggestions fixes you up.