Clutch Replacement

Introduction

Clutch replacement on 924/944/968 models is a substantial undertaking requiring transaxle removal. The following estimated labor times apply:

Vehicle	Time (hours)
944	16
944 Turbo (two-piece crossover pipe)	20
944 Turbo (one-piece crossover pipe)	24

Tools

• Metric socket and wrench set
• Jack stands
• Floor jack
• Clutch alignment tool (944-specific or metric universal)
• 8mm cheesehead tool (12-point internal socket)
• 12mm cheesehead tool (for flywheel bolts)
• Slide hammer bearing puller
• Screwdrivers
• 150mm long 8mm thread bolt (for pilot bearing removal — catch-behind-head method)
• Pliers (locking preferred)
• Hammer
• MoS2 grease

Other Procedures Referenced

• EXH-01 Exhaust Manifold Removal and Installation
• TRANS-03 Transaxle Removal and Installation
• IGN-02 Speed and Reference Sensor Replacement
• BOLT-01 Allen Head and Cheesehead Bolt Removal

Removal

1. Remove the exhaust system as described in EXH-01. On 944 Turbo models, note the crossover pipe configuration (one-piece or two-piece) before disassembly.

2. Remove the transaxle following the procedure in TRANS-03. This is the most time-consuming portion of the job.

3. With the transaxle removed, inspect the flywheel surface and pressure plate for scoring, heat cracks, or glazing before proceeding.

4. To prevent engine rotation while loosening the pressure plate bolts, use one of the following methods:

   • Impact wrench (fastest and least risk of damage)
   • Insert a screwdriver between two pressure plate bolts to lock rotation
   • Hold the crankshaft pulley with a 15/16" socket on the crankshaft bolt
   • Use a Porsche flywheel lock tool
   • Clamp a locking plier on the edge of the flywheel

5. Loosen ALL six pressure plate bolts by one turn before removing any of them. This prevents warping the pressure plate flange. Follow the procedure in BOLT-01 to avoid stripping the cheesehead bolts — a 12mm 12-point internal socket is required.

6. Once all bolts are loose, remove them evenly in a star pattern.

7. Remove the pressure plate assembly and clutch disc. Note the orientation of the clutch disc (the side marked "Getriebeseite" or "Transmission Side" faces the transaxle).

8. Inspect the flywheel surface. If resurfacing is required, have it machined before reinstallation.

9. Remove the pilot bearing from the center of the crankshaft using one of three methods:

   • Slide hammer bearing puller — most reliable method; attach to the bearing bore and extract.
   • Catch-behind-head bolt method — thread a 150mm long 8mm bolt into the bearing until the head catches behind the inner race, then use a slide hammer or lever to pull.
   • Grease-pack/wooden-dowel method — pack the bore completely with grease, insert a close-fitting wooden dowel, and strike sharply with a hammer; hydraulic pressure drives the bearing out. Repeat as needed.

Note: This is an excellent opportunity to replace the rear main oil seal while the flywheel is removed and access is unobstructed.

10. Remove the release bearing and inspect the release lever, pivot shaft, and guide sleeve for wear.

Installation

1. Install the new pilot bearing into the crankshaft bore using a suitable driver or socket that contacts only the outer race. Do not press on the inner race. Apply a thin film of MoS2 grease to the inside surface of the bearing.

2. If the guide sleeve is being replaced, install it and torque the guide sleeve bolts to 15 Nm / 11 ft-lb.

3. Apply MoS2 grease to the following contact points:

   • Inside surface of the guide sleeve
   • Release lever bearing surfaces (both pivot points)
   • Release lever rubbing surfaces against the release bearing
   • Socket for the slave cylinder piston
   • Splines on the clutch disc hub
   • Splines on the driveshaft end (transaxle input shaft)

Note: The Porsche shop manual specifies white solid lubricating paste (AOS 126 0006) for some of these points. This material hardens over time and can cause sticking. Use MoS2 grease instead.

4. Install the new release bearing on the guide sleeve.

5. Position the new clutch disc with the correct face toward the transmission ("Getriebeseite"). Insert the clutch alignment tool through the disc hub and into the pilot bearing to center the disc.

6. Place the new pressure plate over the disc and onto the flywheel dowel pins.

7. Install all six pressure plate bolts finger-tight before torquing any of them. Torque in a star pattern to 25 Nm / 18 ft-lb.

8. Remove the clutch alignment tool.

9. Install the flywheel. Torque flywheel-to-crankshaft bolts to 90 Nm / 65 ft-lb.

10. Reinstall the transaxle per TRANS-03. When joining the engine and transaxle, take care not to allow the weight of the transaxle to hang on the clutch disc — keep it supported on the jack until the input shaft is fully seated.

11. Torque the clutch housing bolts to 75 Nm / 54 ft-lb.

12. Torque the transaxle carrier to body fasteners to 46 Nm / 33 ft-lb.

13. Install the slave cylinder and torque its mounting bolts to 21 Nm / 15 ft-lb.

14. Install the starter and torque mounting bolts to 45 Nm / 32 ft-lb.

15. On early vehicles, torque the engine/clutch housing support bracket to 42 Nm / 30 ft-lb.

16. Set the pivot shaft retaining screw to 9.5 Nm / 7 ft-lb and the pivot shaft locking nut to 7.5 Nm / 6 ft-lb.

17. Reinstall the exhaust system per EXH-01.

18. Reinstall the speed and reference sensors per IGN-02.

19. Bleed the clutch hydraulic system and verify full clutch engagement and release before road testing.

Torque Specifications

Fastener	Torque
Flywheel to crankshaft bolts	90 Nm / 65 ft-lb
Guide sleeve bolts (if replaced)	15 Nm / 11 ft-lb
Pressure plate bolts	25 Nm / 18 ft-lb
Clutch housing bolts	75 Nm / 54 ft-lb
Pivot shaft retaining screw	9.5 Nm / 7 ft-lb
Pivot shaft locking nut	7.5 Nm / 6 ft-lb
Transaxle carrier to body	46 Nm / 33 ft-lb
Clutch slave cylinder mounting bolts	21 Nm / 15 ft-lb
Starter mounting bolts	45 Nm / 32 ft-lb
Engine/clutch housing support (early vehicles)	42 Nm / 30 ft-lb