DIY clutch replacement 997

[leocanto]

Hello,

I'm getting ready to replace the clutch on my 2006 997 and I'm having a very hard time finding a DIY online (to be honest, I can't even find a decent service manual online to buy). I have even searched for the 996 but the link that I found isn't working.

Any help?? If you know where I can find for the 996 that should work also!

Thank you very much!!!

Cheers,

Edited December 15, 2011 by leocanto

[logray]

The 996 procedure should be very similar.

[Steen Jensen]

Pretty much everything you need to know...http://www.c-speedr.com/howto/996rms/rms1.php

[leocanto]

This is a very good link Steen!!! Thank you!!!

[leocanto]

Ok, so I replaced the clutch!!! Not the easiest thing but not impossible, just a lot of work (a friend of mine that have a good understanding of cars helped me). The biggest issue was the clutch slave cylinder...we had a hard time putting it back after transmission was in place. We had to disconnect the tubing for better handling...then had an issue placing into the cylinder. Then, we took the cylinder out again, was able to put it all at once but then had to bleed the system...with a bad bleeder...long story short, the transmission work was around 6hrs (with lunch and getting some extra parts) and an additional 4-5hrs dealing with clutch, bleeder, brake fluid, getting a new bleeder, etc... So, whatever you do don't disconnect the slave cylinder and tubing unless you are ready to deal with bleeding the system. I will post some pictures later, the process is very similar to the 996...

One final issue...after everything was complete, the day after my air bag light decided to come on!!!! Probably because battery was unplugged for a long time...anybody near Houston with a durametric tool that I could use to turn it off??

[logray]

Nice work and you saved yourself some serious money doing it yourself!!!

That slave cylinder can be a pain in the ***.

[Doug_B_928]

Ok, so I replaced the clutch!!! Not the easiest thing but not impossible, just a lot of work (a friend of mine that have a good understanding of cars helped me). The biggest issue was the clutch slave cylinder...we had a hard time putting it back after transmission was in place. We had to disconnect the tubing for better handling...then had an issue placing into the cylinder. Then, we took the cylinder out again, was able to put it all at once but then had to bleed the system...with a bad bleeder...long story short, the transmission work was around 6hrs (with lunch and getting some extra parts) and an additional 4-5hrs dealing with clutch, bleeder, brake fluid, getting a new bleeder, etc... So, whatever you do don't disconnect the slave cylinder and tubing unless you are ready to deal with bleeding the system. I will post some pictures later, the process is very similar to the 996...

One final issue...after everything was complete, the day after my air bag light decided to come on!!!! Probably because battery was unplugged for a long time...anybody near Houston with a durametric tool that I could use to turn it off??

Looking forward to seeing pics.....

[Steen Jensen]

_leocanto

_{Congratulations!}

_{I always like to say working on these cars is not rocket science...just nuts and bolts and elbow grease. Always feels good to accomplish the work yourself and gives you a better understanding of the car. I used a few swear words with that **** slave cylinder too.}

[phillipj]

Ok, so I replaced the clutch!!! Not the easiest thing but not impossible, just a lot of work (a friend of mine that have a good understanding of cars helped me). The biggest issue was the clutch slave cylinder...we had a hard time putting it back after transmission was in place. We had to disconnect the tubing for better handling...then had an issue placing into the cylinder. Then, we took the cylinder out again, was able to put it all at once but then had to bleed the system...with a bad bleeder...long story short, the transmission work was around 6hrs (with lunch and getting some extra parts) and an additional 4-5hrs dealing with clutch, bleeder, brake fluid, getting a new bleeder, etc... So, whatever you do don't disconnect the slave cylinder and tubing unless you are ready to deal with bleeding the system. I will post some pictures later, the process is very similar to the 996...

One final issue...after everything was complete, the day after my air bag light decided to come on!!!! Probably because battery was unplugged for a long time...anybody near Houston with a durametric tool that I could use to turn it off??

If you have good realtionship with an indie in the area they should be able to clear that code for you for nothing.. Takes about 30 seconds..

Congrats on the DYI by the way! Good job!!!!

Edited December 22, 2011 by phillipj

[leocanto]

Ok, sorry for the delay on uploading the pictures...but after holidays, NYE, etc... I'm finally ready! As for the steps, the link given by Steen (http://www.c-speedr....996rms/rms1.php) shows everything that you need, with minor differences (for example the shift cables are slightly different but not much). As I mention on Dec 20th, the slave cylinder is a "lovely" piece of engineering and it will give you trouble...whatever you do don't take it a part, it won't help....try to have in place before the transmission is all back, if possible, if not you will have to work to get in place.

So here are a few pictures, not much since the link above give you a very good step by step explanation!

Thank you very much for all your help!!!

My next step is to fix the airbag error, I will be placing the link below as soon as I have the topic started.

securing the car.

removing axles

securing transmission

Pressure plate, clutch disk and flywheel (we actually believe that the pressure plate was the problem)

Engine - IMS happy to see that it was dry, only clutch dust

New seal

New clutch and pressure plate in!

Edited January 17, 2012 by leocanto

[leocanto]

Here is the link for the airbag light post

http://www.renntech.org/forums/topic/40582-porsche-carrera-997-manual-c2-57k-airbag-light-after-clutch-replacement/

[Doug_B_928]

Wow, impressive! Thanks for posting the pics.

[cPapachristou]

nicely done! i put a southbend stage 5 dual feramic in my audi a4 after going to a big turbo. it was about a ten hour job as yours was (definitely could have been quicker if i had all the tools laid out), having the right tools can make all the difference for sure. It was funny when i was at the dealer getting the seal and the single use stretch bolts. They couldnt believe i was DIYing a clutch. They acted shocked, like it was impossible for the home mechanic. Not much to it actually. Just a lot of pain in the *** work and busted knuckles. Beer always eases that pain tho.

I know ill be putting one in this car in a year or two. I want something that can handle launches pretty regularly.

[racerken]

Hi, I have 45k (stop-n-go 6 miles to office x 365 days/year x polar vortex) on my 05 997 and the clutch now has to go down to 1cm of the floor in order to shift. I think I'm near the end of life. That said, I have a bad-arse 997 driven every day in rain/shine/snow/ice. I can tell you that this car is designed for -15F start-up, no warm up, drive to work.... All is well.

My question to you is whether the fly wheel was worth replacing? I noticed that you suspected the pressure plate. Do you have a picture of the fly wheel surface? I'm just wondering if I spend all this time and effort, perhaps I should just change the fly wheel??????

Thanks

[cam2008]

Ok, so I replaced the clutch!!! Not the easiest thing but not impossible, just a lot of work (a friend of mine that have a good understanding of cars helped me). The biggest issue was the clutch slave cylinder...we had a hard time putting it back after transmission was in place. We had to disconnect the tubing for better handling...then had an issue placing into the cylinder. Then, we took the cylinder out again, was able to put it all at once but then had to bleed the system...with a bad bleeder...long story short, the transmission work was around 6hrs (with lunch and getting some extra parts) and an additional 4-5hrs dealing with clutch, bleeder, brake fluid, getting a new bleeder, etc... So, whatever you do don't disconnect the slave cylinder and tubing unless you are ready to deal with bleeding the system. I will post some pictures later, the process is very similar to the 996... One final issue...after everything was complete, the day after my air bag light decided to come on!!!! Probably because battery was unplugged for a long time...anybody near Houston with a durametric tool that I could use to turn it off??

How high did you jack up the car to get the tranny out?

And did you do the RMS? Easy?

Edited January 8, 2015 by cam2008