Squeaky, creaky spring noise from clutch in/out at rear

[Eric (Plug Guy)]

OK, posted this to Loren, got some great advice (thank you).

Would appreciate any opinions on those who've been down this road.

2004 C4S Cab, 16.5k miles, dealer maintained since day one, no tranny issues, etc. Engine was replaced in late May (Porsche's tab, thank you), and at that time, the top tech who does all the svc on my car did the job. He had the tranny out, so we looked at the clutch just in case, and in his opinion, it looked like new.

All lube points were taken care of during the engine swap and the car runs like a champ (though I do have to go through break in again).

A few weeks prior, I did hear a slight noise when I was almost ready to fire the engine up and was pushing in the clutch, but I did not give it a second guess.

So a few days after this is all done (engine died while driving, no idea what it was, but engine was replaced with new), I notice as I push the clutch in before I start up in the garage, I can hear that spring noise. So I stop, and release the clutch, and can hear it on the up travel too. I figure it's related to the pedal and I'll deal with it later.

Clutch travel is normal, engages where it always has, no trouble with tranny/gears/etc. Engine sounds great (PSE), so while driving, you don't hear it.

I swing by the dealer for a review, and the tech can hear it quite well, and it seems to be stronger from the rear.

I get out while I had a tech lube the pedal points, and he presses in then lets out, and I too can hear it from the rear wheel well quite easily. Lube to the pedal points does not change the noise at all.

So, there are some opinions that this is common, no problem other than noise, drive on.

There are others, dealer included, who say I need to replace the pressure plate, though all the internals were fine upon inspection back in May.

And others are suggesting slave cylinder (lubed), other points along the way (all lubed during engine swap), etc.

So I'm stumped. I don't want to risk anything (and don't think I will should I opt to leave it alone), but I also feel like something is amiss, and should be rectified. But most folks agree that a pressure plate should not be shot at 16k miles, or that it may not be the root cause. Is there a cable we've missed, or a lube point we should hit?

Any other suggestions? And I'm no mechanic, so this may be something I'd do on my own if simple, or I may ask the dealer to do it. But I'd really appreciate any help from someone who may have experienced this same problem.

Thanks!

Edited August 5, 2008 by Eric (Plug Guy)

[ADias]

Eric:

I had the same thing on my 996 C4, but I only noticed it in my quiet garage, never in regular use. I never fixed it. I asked the dealer about it - he said it was nothing that would become worse. You can fix it under warranty, but chances are it will return.

[rattles]

Eric,

My 99/996 manual had similar problems, there is a TSB that covers it. I thought that they had fixed the problem for the 2004 models but it would be worth double checking with your dealer.

They had 4 attempts to fix my car but finally had to remove the gearbox and replace the throw out mechanism. No problems since then and that was 8 years ago.

OK, posted this to Loren, got some great advice (thank you).

Would appreciate any opinions on those who've been down this road.

2004 C4S Cab, 16.5k miles, dealer maintained since day one, no tranny issues, etc. Engine was replaced in late May (Porsche's tab, thank you), and at that time, the top tech who does all the svc on my car did the job. He had the tranny out, so we looked at the clutch just in case, and in his opinion, it looked like new.

All lube points were taken care of during the engine swap and the car runs like a champ (though I do have to go through break in again).

A few weeks prior, I did hear a slight noise when I was almost ready to fire the engine up and was pushing in the clutch, but I did not give it a second guess.

So a few days after this is all done (engine died while driving, no idea what it was, but engine was replaced with new), I notice as I push the clutch in before I start up in the garage, I can hear that spring noise. So I stop, and release the clutch, and can hear it on the up travel too. I figure it's related to the pedal and I'll deal with it later.

Clutch travel is normal, engages where it always has, no trouble with tranny/gears/etc. Engine sounds great (PSE), so while driving, you don't hear it.

I swing by the dealer for a review, and the tech can hear it quite well, and it seems to be stronger from the rear.

I get out while I had a tech lube the pedal points, and he presses in then lets out, and I too can hear it from the rear wheel well quite easily. Lube to the pedal points does not change the noise at all.

So, there are some opinions that this is common, no problem other than noise, drive on.

There are others, dealer included, who say I need to replace the pressure plate, though all the internals were fine upon inspection back in May.

And others are suggesting slave cylinder (lubed), other points along the way (all lubed during engine swap), etc.

So I'm stumped. I don't want to risk anything (and don't think I will should I opt to leave it alone), but I also feel like something is amiss, and should be rectified. But most folks agree that a pressure plate should not be shot at 16k miles, or that it may not be the root cause. Is there a cable we've missed, or a lube point we should hit?

Any other suggestions? And I'm no mechanic, so this may be something I'd do on my own if simple, or I may ask the dealer to do it. But I'd really appreciate any help from someone who may have experienced this same problem.

Thanks!

[Eric (Plug Guy)]

Eric,

My 99/996 manual had similar problems, there is a TSB that covers it. I thought that they had fixed the problem for the 2004 models but it would be worth double checking with your dealer.

They had 4 attempts to fix my car but finally had to remove the gearbox and replace the throw out mechanism. No problems since then and that was 8 years ago.

Thanks....TSB no longer applies to '04, they changed some things. Still hoping it will go away same way it arrived.....out of the blue. ;)

[usc e46]

Drive the car around a little (get it warm) and pull over with the door open and pump the clutch a few times; is there still a noise? My car does that when it is cold, but the noise goes away with a little driving. I had the clutch, pressure plate, flywheel, and lever replaced 9,000 miles ago. About 250 miles ago I had the whole actuation system replaced and flushed (master/ slave) because of other issues (probably just needed a bleed). The noise is slightly less, but still there-- it is the release lever and pressure plate. I wouldn't worry about it, I noticed it and replaced everything in that area (for other reasons) but the sound never changed. If Porsche wants to pay for it, I would have them attempt to fix it, if not I wouldn't think about it.

There is a chance: pressure plate is cracked.

[Eric (Plug Guy)]

Drive the car around a little (get it warm) and pull over with the door open and pump the clutch a few times; is there still a noise? My car does that when it is cold, but the noise goes away with a little driving. I had the clutch, pressure plate, flywheel, and lever replaced 9,000 miles ago. About 250 miles ago I had the whole actuation system replaced and flushed (master/ slave) because of other issues (probably just needed a bleed). The noise is slightly less, but still there-- it is the release lever and pressure plate. I wouldn't worry about it, I noticed it and replaced everything in that area (for other reasons) but the sound never changed. If Porsche wants to pay for it, I would have them attempt to fix it, if not I wouldn't think about it.

There is a chance: pressure plate is cracked.

Just did a 250 mile run today with my son. Up and down some nice mtn roads, great twisties, and some great food in between. :D

Could hear it at a stop light after the first 100 miles or so, and plenty of other stops along the way back. I do not believe hot/cold affects it at all. But for now, I'm driving it as is.

Thanks!

[dcboxster]

Drive the car around a little (get it warm) and pull over with the door open and pump the clutch a few times; is there still a noise? My car does that when it is cold, but the noise goes away with a little driving. I had the clutch, pressure plate, flywheel, and lever replaced 9,000 miles ago. About 250 miles ago I had the whole actuation system replaced and flushed (master/ slave) because of other issues (probably just needed a bleed). The noise is slightly less, but still there-- it is the release lever and pressure plate. I wouldn't worry about it, I noticed it and replaced everything in that area (for other reasons) but the sound never changed. If Porsche wants to pay for it, I would have them attempt to fix it, if not I wouldn't think about it.

There is a chance: pressure plate is cracked.

Just did a 250 mile run today with my son. Up and down some nice mtn roads, great twisties, and some great food in between. :D

Could hear it at a stop light after the first 100 miles or so, and plenty of other stops along the way back. I do not believe hot/cold affects it at all. But for now, I'm driving it as is.

Thanks!

Interestingly, my 996 C2 Cab has a slight squeaky noise when engaging the clutch, but only noticable in dry humid weather. If its cold or raining (therefore more moisture in the air) there is no squeak at all. I've heard that the problem is common too and most people leave it.

Dave

[Benjamin Choi]

Drive the car around a little (get it warm) and pull over with the door open and pump the clutch a few times; is there still a noise? My car does that when it is cold, but the noise goes away with a little driving. I had the clutch, pressure plate, flywheel, and lever replaced 9,000 miles ago. About 250 miles ago I had the whole actuation system replaced and flushed (master/ slave) because of other issues (probably just needed a bleed). The noise is slightly less, but still there-- it is the release lever and pressure plate. I wouldn't worry about it, I noticed it and replaced everything in that area (for other reasons) but the sound never changed. If Porsche wants to pay for it, I would have them attempt to fix it, if not I wouldn't think about it.

There is a chance: pressure plate is cracked.

Just did a 250 mile run today with my son. Up and down some nice mtn roads, great twisties, and some great food in between. :D

Could hear it at a stop light after the first 100 miles or so, and plenty of other stops along the way back. I do not believe hot/cold affects it at all. But for now, I'm driving it as is.

Thanks!

Interestingly, my 996 C2 Cab has a slight squeaky noise when engaging the clutch, but only noticable in dry humid weather. If its cold or raining (therefore more moisture in the air) there is no squeak at all. I've heard that the problem is common too and most people leave it.

Dave

i had my clutch replaced with all new parts including bolts and flywheel all factory about 5K miles ago.

it's likely the pressure plate and can't be avoided. even if you get a new one there's no guarantee it'll be squeak free.

i'm just considering it a quirk/character of owning a porsche 911 and have learned to live with it. i don't notice it unless i'm thinking about it.

enjoy the drive. it's quite common.

[Foster]

I just replaced my clutch and pretty much everything in the bell housing at a little over 60k.

It was the original clutch.

:renntech:

I didn't have a squeak but it just felt really heavy and 'scratchy'.

When I got it apart it was all bone dry. Not even a hint of lube. Even a little light rust.

I put MPO on the guide tube and a little smear on the throwout bearing where it contacts the pressure plate.

The shaft splines, contact points of the release lever and throwout bearing, and tip of the slave cylinder, got 3EP.

The ball journal was left dry.

All that comes out of the TSBs and it's slick as snot and less than half as heavy.

If it's squeaking it has to be one of the listed contact points. You might try removing the slave and cleaning and relubeing the tip.

Otherwise it sounds like you'd need the drop the trans and clean and relube everything.