[kwikt]

Well I thought it would last longer than 120,000 miles but it finally went out last night. Clutch peddle went sorta to the floor, smell of burning clutch, barely made it home with alot of vibration which has been getting worse as time went on. So I plan on tearing into this today but I can't find the diy'er on this project. Also does anyone know who has the best price? Any info would greatly be appreciated. Thanks!!





Kevin

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[DaveN]

Not sure what a DMF is (and I'm not sure I want to know <img src="/forum/images/smilies/968/tongue.gif" class="smilie" alt="" /> ) but I have a DIY for a 944 clutch job. Not sure how close it is to a 968 (Flash?) but that's what I used on my 944 with 98% success. I hear you can do the clutch in a 968 without actually dropping the rear out, you can slide everything back just enough to make a gap and with the right tools <img src="/forum/images/smilies/968/wink.gif" class="smilie" alt="" /> do the job in place.

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[PorscheDude]

Try sunset if you want a stock DMF.

RS barn upgrade is a little less by time you get all the parts you need.



do a search here for carnwell

You will find the oem service manual.



Clutch job is far easier in the 968.

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[kwikt]

Alright, I got the cover off and apparently the clutch fiber from the disc is everywhere. The flywheel seems to have alot of play when rotating with clutch back and forth. Now I hit a roadblock!!! How do I remove the guide tube that is in front of the clutch pressure plate. Does the complete clutch fork assembly have to be removed????



Kevin

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[RS Barn]

You need to remove the 6mm locking nut amd back out the 6mm bolt that retaines the fork pivot. We usuall need to put an 8mm bolt in the end of the pivot shaft and use a big a_ _ slide hammer with plenty of wd40 or such to get the pivot shaft out.

The guide tbe is easy once the intermediate shaft has been moved back

Pete

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[kwikt]

Clutch is out!!!!! There is no disc fibre left on the side facing the flywheel just chunks HMMMMM. Seems like the disc fibre separated from the disc. This clutch is a Sachs. Well on to the flywheel, almost forgot,,,, gotta remove the speed sensor before removing flywheel.



Kevin

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[kwikt]

Well I got the new flywheel and put it on last night. What a b#@ch trying to get it aligned onto the crankshaft with the car being on jackstands and also very limited room to torque the bolts. If I only had a lift. I should be getting my clutch disc,needle bearings, etc. today and can't wait to get it back together and on the road. It "should" run alot smoother.



Kevin

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[PorscheDude]

Yea, I did mine last year. I is a bitch on your back, but not to hard.

Sounds like you are ,aking good progress.



Have you changed the clutch master, slave and line? Now is a great time.





Imagine a clutch job on a 951.....

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[flash]

don't feel bad - i've done mine 5 times now on my back, and will be doing it again soon

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[Anchorman]

That's because you, Flash, are an unusual guy!!!



C'mon, stop fooling with this flywheel stuff and get on to some serious stuff - like rotors, calipers, etc.

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[flash]

lol - almost there

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[kwikt]

Clutch is done and back on the road!!!!!!!! I just can't believe how much smoother it runs and shifts. Gone is the peddle vibration and shifter vibration. Can't wait to put the G-tech to er to see what she runs now. Thanks guys for the support!!!



Kevin

72 911T/E

92 968

96 PW50

01 HD Fatboy

03 330i

07 F150

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[PorscheDude]

Great news! Very rewarding to DIY?

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[kwikt]

Crap..... should have replaced the clutch master cylinder while the car was down. So today was replace the "leaky clutch master cylinder day". WHAT A PITA. I almost believe the clutch and flywheel replacement was easier. Now the clutch peddle is smooth as silk(just like the wifes' BMW).





Kevin

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[flash]

did you replace the high pressure line at the same time? if not, and it's original, prepare for it to blow

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[kwikt]

Hey Flash, replaced it about 5 months ago.



Kevin

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[flash]

very cool - it's a bit disturbing how frequently that thing blows after the other parts are changed and it is skipped

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[xrad]

Kwikt: Did you remove the fuse box to get top access?

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[kwikt]

No.... I thought about it but took Flashs' advice and took the gymnastic approach. If I was 3'2" tall the job could easily have been done while working from the drivers floorboard. But being 6'3" it was almost humanly impossible. At 1 point I got stuck under the steering column and almost had to call 911 with the jaws of life but didn't want to risk chopping the 968. The job took me almost 4 hours. If I was to do it again it would probably take me 2.5 to 3 hours.



Kevin

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[DaveN]

Herein lies the lesson. I am 6' 4"/230ish and have been under the dash only to find it took me 30 minutes to get 3 zap straps on a wire with the finger tips of one hand and a spine brace when I extricated myself <img src="/forum/images/smilies/968/blink.gif" class="smilie" alt="" />

So when I needed my master done I drove it to my mechanic who is 5' 7" and 150 lbs wet, walked away and said call me!

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