Porsche Enthusiasts Club Forum

Hi everyone,

I've finally found some time to do my clutch, in fact I've got the week off work, so this should give me plenty of time in case I mess it up!

DAY ONE
Well I thought I'd give myself an easy start by spending the day getting myself organised (something I'm notoriously bad at) labelling boxes, arranging my tools, covering everything with penetrating oil and sorting out the various guides (haynes,clarks and the porsche pdf). This didn't take long so I thought I might as well make a start by taking the exhaust off. How difficult could that be? Very, as it turns out! The exhaust to manifold bolts were severely rusted and it's extremely difficult to get the top of the bolt. Well, it came off in the end, after 2 hours! I guess I won't be getting a job at Kwikfit!
Next, was the speed sensors, the bolts came out easy enough and the front sensor came out with a bit of force but the rear sensor just won't budge. So if anyone out there knows a good way to get it out please let me know or would it be ok to leave it in place and undo the electrical connection?
Another update tomorrow.

All the best,

Andy

Good on you. When you got some practice in would you like to do mine.

mines just starting to judder sometimes, so i'll join the queue

O no!

Does it do that in all gears? Mine does it very occasionally but only on engaging 1st..

yes only when pulling away in first and mainly when the engines cold, not so bad once warmed up, suspect the rubber do-nut starting to break up as i think its still the orig clutch

Hi everyone,

DAY TWO
Well, I decided to get the gearbox out today and it was going quite well (allbeit slowly) as it's generally a case of just unbolting things. Until it came to the point of actually taking it out. It moves back until it hits the spare wheel well then I just couldn't move the transmission coupling back to release the gearbox. I think with hindsight it's probably better to try and move the coupler back while the gearbox and TT are still attached as they would be perfectly aligned. I could of cause put them back together and start again but I think I'll go for plan b which is to drop rear suspension (ala "The Garage",if you saw that) enough so the gearbox can slide out underneath the spare wheel well (it was sorely tempting to get the angle grinder out and cut it off). Anyway, I think this is better way to go as it'll be alot easier to put back together this way. Hopefully tomorrow I might actually to the clutch!

All the best,

Andy

I recall from a conversation with Camtune a few months ago there is a special porsche tool to aid gearbox removal.
Sorry I know that doesn't help!

Hi everyone,

DAY THREE

Not a huge amount of progress today as I've come down with a stinking cold (probably crawling around on the freezing cold floor hasn't helped). But I did manage to the get the gearbox out! hooray. What I did in the end was to bolt it back together then the coupling slid back quite easily, wish I'd did that yesterday. I decided against droping the torsion bar housing as this looked more trouble than it was worth plus it's surrounded by all the fuel/brake pipes etc.
Then I moved up the front and took the starter and the slave cylinder out. Then I played hunt the bolts for the engine cover and once you find them, then you've got to work how out how to get a spanner on them! Oh well, I suppose porsche designers of the eighties didn't think that some muppet twenty years from then would be crawling around underneath, trying to fix them.
Hopefully I'll see a clutch tomorrow!

All the best,

Andy.

Hi, everyone,

DAY FOUR

If I get to "DAY FORTY-TWO" can someone come round and shoot me. Anyway, it's pretty slow going, mainly because I'm on a slight incline. So, for safetys sake, I want to keep at least two wheels on the ground at any one time. This means, as I was doing the TT today, I have to keep moving the axle stands backwards and forwards. Not only this but you have to stop the TT resting on the torsion bar housing and support the back of the engine when the TT comes out. So can I strongly suggest if you're planing to change your clutch yourself (hope I'm not putting you off) that you find level ground and use four axle stands. Also, if you can use a pit this would make things ten times easier. This process doesn't actually need a huge amount of technical knowledge it's generally just unbolting things and moving things. It's just that those things are big and hard to get at.
I thought this was going to take about three/four days (how wrong was I). I'm back at work Sunday,it looks like I might have to dust off my push bike

All the best,

Andy

When you said "day 42" I thought of that guy from Big Brother reading out the days activities
10/10 for persistence with this one. It's good to hear from another owner having a go. Maybe you could write it up for the mag?

Andy - you have got to the hard bit, once you have got the clutch housing off it's easy going.

Rich

Nah that's half way he then has to put it all back together
As Haynes would say reassembly is the reversal of removal....

Thanks for the encouragement guys, I need it!

Andy.

Once you got it all in bits it's got to be easier to put it back together. Out of interest what states your rear transmition mount in? Was considering ordering a new one if I have to do mine as it seems like the ideal time to change it. (Fancy a solid one to see if it really does improve the gear change.) It will be very satisfying when it's all back together! Just think of the money your saving
I'm commuting by train at the mo' Saving a fortune. They don't bother to sell me a ticket most days Spent £1.05 this week in train fairs. Because my tyres are bald & all the Falkens in the country in my size are sold out.