Wear Limit on Clutch Disc

[jporter]

I have a 98 Boxster with a 2.5L engine and I'm in the process of replacing the RMS and the other suspect leakers like the crankcase and intermediate shaft bolts. I'm also replacing the AOS as it has decided to spray a significant amount of rust preservative on the passenger side of the engine. I will also likely replace the clutch and would like to know the original specification on the thickness and the wear limit. I plan to see if I can come up with a way to monitor clutch wear when everything is reassembled.

Does anyone know what the thickness specifications are for a new clutch disc as well as the disc wear limit for a 2.5L engine?

[WARDHOG]

I have a 98 Boxster with a 2.5L engine and I'm in the process of replacing the RMS and the other suspect leakers like the crankcase and intermediate shaft bolts. I'm also replacing the AOS as it has decided to spray a significant amount of rust preservative on the passenger side of the engine. I will also likely replace the clutch and would like to know the original specification on the thickness and the wear limit. I plan to see if I can come up with a way to monitor clutch wear when everything is reassembled.

Does anyone know what the thickness specifications are for a new clutch disc as well as the disc wear limit for a 2.5L engine?

I would and have replaced the clutch disk when the RMS have been changed. $250 now or $1500 later.

[jporter]

The following is an update on the clutch wear.

I ordered a new clutch disc and when it arrived I found that it was a different size than that already on the car. The following picture compares the new disc with the old disc and pressure plate.

The outside diameter was the same for both discs, but the inner diameter was smaller for the new disc. Although the new disc would have full contact on the flywheel, only the outer portion would be in contact with the old pressure plate. I’m guessing this is not an issue with the new pressure plate.

I also measured the thickness of the new and older discs and found them to be close in overall thickness. I then measured the depth from the face to the rivet and found that the old disc actually had thicker material on the face as shown in the pictures that follow. The depth to the rivet on the new disc ranged from .040 inches to .050 inches and the depth on the old disc measured .070 inches to .105 inches. As a result I put the old disc back in the car and returned the new disc to the parts dealer.

One last comment is that I don’t know how many miles are on the old clutch since I have only had the car for the last 15K miles of the 85K total.