Long story short, long time lurker first time poster... Thanks for all the knowledge so far.

Replaced a slave and accumulator in a 996TT some years ago (~2yrs) this morning, clutch pedal, flat on floor, have it towed. CHF11S overflowing from under bonet and power steering resivoir is nearly empty (top off) the weird part is now clutch pedal is ROCK HARD, is nearly impossible to press down, have to wait for it to bleed down and clutch does not release. I'm 99.9% sure it's a slave and accumulator again, but the .1% is worry I'm also missing something else. Aluminum flywheel and Spec clutch are in vehicle.

 

Maybe. Tough call. As you know a pedal that is hard after car shut off or one that gets hard with engine off after 10 to 35 clutch pedal depresses is sign the accumulator is bad.

If after one gets the pedal hard and then starts the engine and lets it idle 20 second then shuts off the engine and find the pedal hard is accumulator or hydraulic power circuit.

If after starting the engine and runnng the engine at idle 20 seconds then shutting off the engine and without turning the steering wheel and without depressing the clutch pedal if the fluid level in the clutch slave cylinder reservior under the panel under the front trunk is high, the clutch slave cylinder is bad.

My 03 Turbo just went through this, but at no time did the pedal reach the floor and want to stay there and the clutch worked just fine with the engine off or on the only difference is with the engine off the clutch was harder to depress and while the engine was running I could feel a very slight (very very slight) judder from the pedal which was the vibration from the pump. Because the accumulator was bad this was not provided the normal dampening of the pump's working.

In your case the situation is muddied a bit due to the aftermarket flywheel and clutch. If the clutch disc or pressure plate has failed, this might account for the clutch pedal's behavior.

Still, I'd be tempted to throw a new accumulator and slave cylinder at the symptoms before removing the transmission to inspect the clutch hardware and linkage in the bellhousing.

However, before you do the accum. and slave cyl. though I assume you will as best you can inspect and even observe if possible the action of all the external clutch linkage to see if there's something wrong that is responsible for the pedal sticking to the floor and the very hard clutch pedal pressure?

Sincerely,

Macster.

 

Hey Zach long time no see!

 

Hey there, finally stepped up your game past Vw's eh? RIP DSR. Moved back up north after school, miss houston big time.

 

The pedal was flat on the floor, with no spring in it, So I checked the reservoir under the hood and the P/S levels. It was obvious that the system had made a mess under the hood. When I filled the P/S fluid and started the car, I lifted the pedal and got some stiffness halfway down, then I lifted and got more and more. then It was near solid and I had to hold pressure down for some time before I could even get it to the floor and activate the clutch switch so I could start it again. Ordered a slave and accumulator from Worldpac with some CHF11S, and we'll go from there I suppose. I come from the Audi side of things, and my Porsche experience came mostly from changing rear mains when the Porsche guys were too busy so I can do a Boxter or 996 NA car clutch or trans like no other.

 

Just my luck, Transmission has to come out. Got the slave and accumulator out and it's the same, except not overflowing into the clutch reservoir. YAY... At least now I can get this DREADFUL Spec clutch out of this thing the last guy who worked on this installed.

 

Going through the same ordeal now. Got the slave replaced no more than a year ago and this past weekend during a run it went dead to the floor and I grinded 4th gear. Pulled it back up with my foot but it won't go full travel so trans can't shift. No fluid leaks, towed the car to the dealer. Porsche tech is checking it out now.

 

There can be a problem with the hydraulic clutch fluid lines that allow them to move axially and allow air to get into the system past the plug in couplers.

A snap ring # 999 230 685 40 (3 required) must be fitted in the groove of the plug in couplings in the area of the plenum chamber, underbody and transmission.

The clutch system must be bled.

Sincerely,

Macster.

 

Thanks for the info I'll relay it to the tech. He had to pull the trans yesterday. I'll let you know what he finds out.