Porsche Enthusiasts Club Forum

From chatting to Jon Mitchell a while back:

For S2s there are two clutch kits made by Sachs - he said to avoid LUK items like the plague. The Sachs clutches differ mainly by one having 3 centre springs and the other having 4. I think he said the 4 spring one is known as the "cup clutch" and it's smoother due to the extra spring improving the cushioning of wheel driven back torque, same as the rubber thingy was meant to when new. Anyway, worth giving him a shout, because with his trade discount and contacts in the fatherland, the cup clutch is more affordable - I think he orders them directly from Germany. About £360-£400 from memory.

Cheers,
George

Hi everyone,

My new clutch is the spring centred one. I believe they stopped selling the rubber ones many years ago because of the problem with the rubber breaking down. But on the one hand it has lasted 21 years and 118k miles but on the other the friction surface was only about just over half worn. So if they had used a spring centred one to begin with it could have lasted untill you needed an engine re-build, say, 200k miles.
Anyway, not much happening on the car at the moment, the slave cylinder hasn't turned up yet and neither have the bolts etc I ordered from local OPC. As two of the bolts are for the gearbox mount there hasn' t been much for me to do although I do now have some very shiny exhaust mounts!

All the best,

Andy

Hi everyone,

It's finished!!!!!
Just completed it this morning and it all seems to work (to my amazement). Anyway, putting it back together is much easier than taking it apart. Only a couple of things worth mentioning, when putting the gearbox back in I'd read people had trouble with the plastic linkage sleeve. What I did was to put it in the gearbox side, then when I offered up the gearbox to the TT I pulled the link shaft through the TT and put it a couple of inches in the sleeve, then when I pushed the gearbox onto the TT it self located. Also, I'd read that bleeding the clutch can be a nightmare and that you have to get the back of the car as high as possible. As my car was pointing slightly uphill with the front jacked up I wasn't holding out much hope. But I fitted an ezibleed kit (the one that works off your spare wheel) after filling up the up the resevoir then opened and closed the bleed nipple a couple of times then pumped the pedal a couple of times, then got an assistant to hold the pedal down while I opened the nipple, we did this a couple of times and it worked (again to my amazement).
So, I've finally got it back together, it was a hard slog, but it is achievable. Technically, in the time its taken me I could have earned the money to get someone else to do it but where's the challenge in that! My original timescale of 3-4 days probably caused me the most frustration as I thought I was getting nowhere. But realistically I think you should give yourself 2 weeks.
Thank you to everyone who contributed, I hope there's some tips in here you might find useful if you fancy having a go yourself. Also, if your local I'm more than happy to come round and delegate!

All the best,

Andy

Congradulations If you did one again bet you could do it faster Will be bringing mine round any day now

Well done Andy, it's been a marathon.

Well done that man

Now you can get back to the fun part of Porsche ownership...driving it!

congrats, you're my hero, now go and enjoy

Top guy well done

Respect...

Hi everyone,

Thanks guys, you're almost making me blush

Its made a heck of a difference, no more bearing whine, no more embarassing clunks as I pull away and perhaps best of all no more backlash (which felt like you were being hit up the rear as you come to a stop). Gear change is now alot smother and my hot start problem seems to have cured itself (perhaps due to cleaned up sensors?). So I'm pretty pleased (and relieved) its now sorted.
One last thing I forgot to mention, I didn't have any problem with stipped out bolts, maybe due to good fortune but more probably due to the fact that I used clarks "bolt wake up". Which is basically, you give the bolts a firm tap with a hammer before undoing and with allen etc bolts you insert the tool, then give it a firm tap, this also makes sure the tool is properly inserted before undoing.

All the best,

Andy

Well done.

Careful though you may find a long line of 44's outside your garage.

hi very impressed, saved a lot of money while you where at it.ive got an 86 turbo, clutch totaly killed.lanchaster porsche norwich £2200.i'll have to have a go myself.how high did you have the front of the car up,also did you put axle stands under the rear jacking points.i have to take the gearbox out of the car because it has an oil leak somewhere.any comments will help.not in any hurry as its a hobby project thanks

Hi Bill (I'm guessing thats your name)

I had the front high enough that I could slide underneath comfortably but not to high as to make it unstable.
Generally, for jacking and axle stands I try and use suspension points as its very easy to damage the chassis. At the rear I put the axle stands under the middle of each swing arm (on the flat surface).
I believe its common for oil to leak out of the axleshaft seals on the gearbox which is quite an easy fix, especially if you've got the gearbox out. You might as well re-pack the cv joints as well while you're there (a gloriously messy job!).
Let us know how you get.

Best of luck,

Andy.

Hi,
Well done Getting it all apart is a big pain.
The transaxle failed on mine so I decided to do the Clutch as I was halfway there..... yeah right! My clutch pretty much looked like yours when I got at it and was on the stops I suspect its what shortened the life of the gearbox although I may be wrong ( just to worry those with original clutches).
I have yet to put it back together as my back is currently a bit like my clutch.
CV joints dead easy but as you say possibly the messiest job in the world!
How hard is the rear main seal? or if it aint broke? etc

Hi jameso,

As you say "if it ain't broke....... so I didn't do the rear main seal as is wasn't leaking (probably the only bit that doesn't) and looking round the internet I've about several people that wish they hadn't bothered as it ended leaking more afterwards.
Good luck putting it back together, it really is alot easier than taking it all apart, I hope you labelled all those bolts!
Hope the back gets better soon (I had a prolapse disc op a couple of years ago, absolute agony!).

All the best,

Andy