dan_189

Hi all,

My clutch booster spring is making a nasty click noise once and awhile. Decided to buy a new one, tried to put it in today but couldn't get the old one out!

So far I have done the following steps:

- remove air vent duct
- removed cruise control switch
- put a pin into the end of the canister
- pushed in the clutch
- removed the C clip

Tried to remove the bolt but it looks like it's not going to get out because of the Gold bracket that's blocking it?

Any ideas?? Car is a 2004 996 C2 (right hand drive).

​I dont have the pin inserted or the clutch switch removed in the image below. Hence why the spring is so stretched but it's the same with the pin inserted.

Thanks!

dan_189

One theory that I'm yet to test as it's late here in Australia, was the clutch pushed in too far? Causing the bolt to be too far and blocked by the Gold bracket? If the clutch was only pushed in half way then the bolt would clear the bracket further up?

RRTEC

bingo. This is it. It has to be pushed in just just enough to clear the pin. What a pain.

dan_189

Huge pain!

Anyway, just got in and pushed the clutch by hand to test this theory but the pin never cleared?

I didn't put the holding pin in though but i'm guessing it wouldnt make much difference if the holding pin is in or not to whether the pin can clear?

fpb111

Try putting the holding pin in the hole in the back of the shaft. Then lightly press the clutch until the pressure is relieved from the pivot pin. The front of the Assy should drop out of the fork on the clutch lever.

dan_189

Hey guys,

Thanks for the responses, when I put in the holding pin I press in the clutch and there is a loud click noise (i'm assuming this is the loading of the spring and then the spring in the tension position ready for removal).

However there is still no clearance for that bolt to be removed? Does the geometry change with the holding pin in place? So maybe just past tension of the spring is where the pedal should be not all the way to the floor?

In the image above the pedal is all the way to the floor as far down as it can go.

dan_189

I've been able to put the holding pin in and relieve the pressure from the pivot pin (with the C clip), to the point where I can move the pin side to side. I just cant see how the pin will clear that gold bracket.

Does the canister come put before the pivot pin with the C clip can be removed?

dan_189

Okay got it out!

Wiggled the bar out and then got hold of it with a set of pliers and pulled it out!

Now the next challenge is getting the new spring into the car...

dan_189

So the second part of this headache is beginning...

What's the best way to get it back in?

I've been trying to manuver it back in whilst the clutch pedal is depressed.

I haven't been able to get it in?

Any ideas? I'm trying to get it to clear the gold brackets so I can attach it to the pedal then release the clutch so the canister finds its way home into the brackets

Ahsai

I have not done this myself but the wsm calls for removing the gold bracket together with the spring canister if you need to remove the latter. There are 3 bolts holding the bracket. Good luck.

Montychristo128

What type of manure are you using? That may be the issue.

Remember only unicorn poop should be used on a 996..

dan_189

Thanks Ahsai, what section is that from?

Access to the bracket is extremely limited so I don't know if I can get to it. I removed it by twisting it and it fell out. Guessing that it just needs the right angle to get back in.

dan_189

Only the finest

DBJoe996

It seems like it would be easier to follow the workshop manual for removal of the clutch pedal and bracket as all one piece

DBJoe996

Installation