Porsche964FP

I recently had an RS clutch/ flywheel, RS engine mounts installed as well as the clutch bled.

The clutch pedal has very little travel, I find myself lifting it up to it's fullest position very often. The biting point is just no good.

I know this could be a slave/ master cylinder, hose issue but my specialist gave it a quick look and couldn't find the source of the issue. Albeit we didn't have much time to experiment to find the answer.

I'm looking for some advise/ insight please.

Thanks in advance.

Rocket Rob

Check your clutch pedal roll pin.

August West

+1 on roll pin...easy to check, easy to fix.

Spongy clutch is usually air in the lines. Travel issues in pedal can point to roll pin failure. Mine disintegrated the day I first got my Porsche...big WTF moment but easy to fix...the Porsche mechanic used a similar diameter metal rod from the crafts store, like Michael's or such, cut it to size, and put the assembly back together...end of story.

Porsche964FP

Thanks for the replies.

You're right, it's a travel issue not spongy. Thing is the mechanic had the floor board up and the pedals in plain view, would he not have seen the roll pin? Or is it located somewhere else?

August West

You'd have to be looking for it specifically. It would become apparent with the floor boards up and when you'd physically move the pedal through it's travel, you'd see that the master cylinder is not getting the full mechanical translation of the pedal effort. The failure of the roll pin can be incremental and not immediately catastrophic, so you might still get master cylinder actuation but not at 100% of expected functionality.

Like I said, mine failed incrementally so that at first it seemed liked it was getting harder and harder to put into first gear, then it would just plain grind in the tranny trying to engage first gear. The pedal felt like crap. Then it went full failure and there was no getting the car into gear.

I hope this makes sense!

August West

Item number 8 in this pictorial! The roll pin acts as a dowel to secure the lever to the shaft. Hope this helps.

Porsche964FP

Thanks for the detailed reply August. Just been reading up past threads now that I know the roll pin exists and is something to check. I'll have a look and see what I find.

It looks like a pretty easy DIY especially when you've got Renlisters at your side.

I'll be getting this one sorted asap, the idea of getting an ear full from the miss whilst stranded somewhere is a chilling scenario! Especially since her clothes now smell of car polish... how else do you clean your polishing cloths!

August West

Just noticed a good pictorial of this whole discussion in the nearby post "Aussie 964C2 Maintenance Diary" from Babalouie complete with a DIY fix...great pictures which detail the whole thing.

Rocket Rob

Wachuko - described the roll pin replacement in this thread. I've done it. Its not too hard.

https://rennlist.com/forums/964-foru...al-solved.html

Porsche964FP

Brilliant thanks again!

Rocket Rob

By the way, I changed out my clutch master cylinder and pedal bushings while I had the pedal assembly out. They are not that expensive and its easy while you have it on the bench.

Porsche964FP

In order to get the roll pin out I need to get part no. 9 off the pedal assembly ( the roll pin hasn't got enough clearance to get out ), how do I do this?

TIA

Rocket Rob

You need to remove the pedal assembly from the car. Once you do, you can then flop the pedal around until you can use a punch to remove the roll pin. The roll pin is what secures part #9 to the clutch pedal shaft.

See the "punch it out photo" here = https://rennlist.com/forums/964-foru...solved.html#21

Babalouie

You see how #9 is connected to that weird spring thingo at the back of the pedal cluster? Undo the clip, slide out the locating pin (#14) and disconnect #9 from the weird spring.

Then #9 will be free to rotate to a more friendly angle, that will allow the whole pin to slide out the back. I know what you mean, with the weird spring controlling proceedings, when you hammer out the rollpin it just jams against something at the back

Porsche964FP

Thanks Gentlemen!

All done! Big difference!

However there is still some small amount of play in the pedal, about an inch. Is this normal?