Well, got my car 2 months ago and it has been a whirl wind on it. BBi clutch slave, knurled and epoxied coolant housing fitting, replaced plastic fitting under oil cooler, plugs, coils, new clutch master, etc.... BTW, 2007 007 TT w/ 44000 miles.

So, I am really getting happy with the car. I have it up on jack stands right now as I just did and oil change and I am chasing two very minor issues that annoy the crap out of me.

First, put in new clutch master cylinder. Now, when I push it down, the last inch or so, before I hit floorboard, I get kinds a crunching sound and feel. It sounds like it is coming from the master. It is only when pushing down, and only on the last inch or so. Not when releasing and the clutch feels incredible other than that. Also, does not do it when I first start, but as the car warms, it does it more and more till it is constant.

The final issue (until I find another one...lol) is that when I let off the gas in gear, I get a little clicking kinda sound. It is hard to hear, but, hey, we know our cars and things others do not pickup on we do. It is annoying me. I am not sure clicking is the best word for it, just kinda a noise. Sounds like it is coming from under the pedal or center console.

Get these two issue fixed and the car is about right. I do smell antifreeze everytime I run it, but I had a few hoses blow in the last 4 weeks dumping all my coolant 3 times all over the engine. I assume it is still burning or drying off as coolant has not dropped, I have no leaks and oil is clean.

Any help is always very much appreciated. Thanks!!!

 

Could it be the sound of the gearbox or engine moving around? I found a similar issue when I pushed hard and then lifted, replacing he motor and trans mounts resolved this.

 

For the clutch, is the vibration like a stiff rubber on rubber feeling or more metallic? I get a funky feeling at the bottom of the clutch movement I put off as a symptom of the power assist stock clutch. It may be the MC instead, since I don't think I would feel a slave funkiness like that in the pedal. I guess another possibility would be TO bearing, but I am not sure I would feel that in the pedal either. Others may know more.

For the drive train noise, does it click when out of gear or only under load? I like the mounts idea too.

Ed

 

Under load

 

Any similar noise when turning (CV clicking) or only forward - back? Any noticeable movement/looseness in the drive train when you hear the click?

Did you notice the clicking before the engine was in & out?

I am hoping these questions and your answers will prompt some other responses.

Ed

 

Check your clutch slave. The push rod, anchor points and fasteners are all tight. Not sure about your car, but in my 997.2, the slave is plastic and the push rod was worn and causing the same problem. After replacing, the clutch felt as new again.

 

Found a few things. First, I have at least 2 broken under body panel stud broken and another 3-4 missing t5 nuts. Welded in new studs, what fun. Wondering if ti could be the underbody flexing when I let off on the gas pedal making the noise since it was not secured.

Since it sounded like it was coming from under neath and a little in front of the center console, under the car this the the front diff and drive shaft area. I put it in gear and checked the driveshaft. it does have just a tiny bit of play side to side. Might be the noise when I let off the gas. How tight should the driveshaft be? Any free play at all, or should it be so tight it will not budge an inch. Could be either problem, but moving the shaft back and forth, it sounded more like that. But I can not test the underpanels on the jacks. Missing 3 studs and an additional 2-3 T5 nuts. This is on the frist two panels fromt the front to rear, so missing 6 connection points. Thoughts?

 

Here is a quick video of me turning the drive shaft back and forth. It really barely moves, but it does move.

 

I will get a video of the clutch noise later. Since I have the under panels all off, working on shaft and a few other things. ****, cant find those T5 underbody nuts anywhere. Going by Porsche Monday to see if they have them. Got my studs back on.

 

Nine times out of 10, every time I pay a visit to the shops, after they worked under the car, some under-panel fasteners would be missing. It just amazes me that they would fix something and left other issues behind. So now whenever I picked up my car after a service, I put it on jack stands and go over every panel fasteners. Sure enough, inevitably 1 or 2 would be missing. I have a bagful of spare fasteners just to secure the panels after their blotch jobs.

 

If the panels are not snug and have some gaps and areas where not fastened, I could see them making a little noise from letting off the gas (and torque). It either has to be that or the drive shaft. Stay tuned for clutch video.

 

LOL, you and I must be in some parallel universe, you don't play hockey by any chance?

Anyway, I JUST went through this with my car. My son (yeah I know I am giving him a loaded gun) was running a "quick" errand when he heard this slapping noise at speed (above 75), so I took it out for a ride. It took me until 80+ to notice it and I thought the noise might be a fender liner on the RF since the nose is an aftermarket piece and doesn't fit the stock liners exactly. So I trimmed the piece a bit so it would sit better, tested and still made the noise.

So I jacked the car up and found 3 sheared off bolts & missing nuts on one side of the panels and it showed signs of scraping. I used a flat ended bolt and ground off the undercoating and epoxied it to the body, sprayed some coating on and used some stainless bolts/washers to secure the panel. No more noise. My guess is they had something sticking the pieces together or otherwise holding them up for the past year I have owned the car.

Now mine was a flapping noise, not clicking, but I can imagine it making that kind of noise depending on what bolts were missing.

I too am often amazed at what happens to vehicles when serviced. I can't tell you how many times I have replaced things like under body panel securing pieces only to find either something else in their place or them missing completely! These broken off bits were a bit surprising though since that means someone torqued them right off (the torque is like 13 in/lbs, just past finger tight).

Ed

 

Yep. 6 fastners missing. Ed, started on exhaust. Then had to take a break because I was going to throw the whole car off a bridge. Ed knows this, but for you who don't, mine has an AWE exhaust on it I do not like. Resonance at idle sucks and the sound at rpm is like a dump truck. Idiot who had the car before me tack welding the damn thing. Cursed enough at it to make a sailor blush. Done for the day, hot as hell outside and I am getting frustrated. That is how **** gets broken and tools thrown....lol.

 

Ed, I am not trying to talk you out of buying this exhaust, I just do not want you to have buyers remorse. It does sound ok in the upper RPM's. It is a full track exhaust and I am not sure street legal. I live in Alabama, and Alabama doesn't really care about anything. We have no emissions testing here.

Now the good new. Looks like just the tips were welded on, which sucks, because I wanted to keep the tips (nice aftermarket Sharkwerx). And back to bad news, no way to get the exhaust off with the tips welded on without removing bumper. Back to good news, it does not look like I will have to hack it up to get it out, so it will be complete, back to bad new, it is hot and I am frustrated, so it may be a few days..... After pulling panels, oil change, welding in new studs, and fighting the exhuast in 98 degree heat for a few hours, it is MILLER time. Oh, I own a Porsche, it is St. Paulies Girl time...

 

^ So they welded the tips onto the exhaust? Thats kinda bizarre..

Honestly, removing the bumper is not bad at all. Takes me all of 20 or 30 minutes to do this. There are lots of good tutorials online that show you how to do this.