Hi All,

I realize that I lurk here more than I post, but I use the search button frequently to learn what I need to know. I have only have my 2000 996 Carrera 2 for about 1.5 years and I am still learning more and more.

Here is my issue/question:

Yesterday I was driving home, very mildly and all of a sudden my clutch pedal got really soft and kinda spongy. Just didnt seem to have the same grab on take off and moving into different gears just felt different.. soft I guess. I did some reading here last night then took the car out, ran the car easily to 6K in first, quickly shifted into second and hit the gas. Noticed the clutch slip. I realize this is likely a clutch issue, but there were no warning signs. What I am wondering is if this could be related to the flywheel, clutch disk, bearing, hydrolics????

I do not have many options here in Idaho for service and I am limited on what I can do in my own garage. I am going to have to drive it to the stealer tomorrow and get it looked at. Would like to be armed with some ideas from the experts on the forum.

I push the clutch in and out with the engine off and it is still very soft, and kinda spongy.

Any ideas or additional things I can check before dropping another 1-2K at the dealer would be great. Car has 65K on the clock, just had 60K service.

Thanks!

Phil

 

Put the car in second gear, put one foot on the brake and one on the clutch. Release the clutch slowly and if the engine slowly responds until stopping then your clutch is OK.

Spongy can be the master cylinder

 

Thanks Steve. Should this be done from a stop?

 

I bet the clutch return spring (in the cabin) has gone. Mine went around 35k miles, it was a fairly inexpensive repair.

 

There is no clutch return spring on the 996. Possible problems could include a worn out clutch disc, sticky slave or bad release lever. Generally, the release lever comes under suspicion when the clutch slips at a high rpm shift and then slowly (few seconds) grabs fully while you remain on the accelerater. If the clutch continues to slip until you lift off the gas, it is probably the disc.

Either way, the tranny would have to be pulled for inspection. There are many dealers who will replace the stock clutch assembly for around $1200. I would also spend the addition $50 and have the release lever replaced too.

 

I misspoke, it's a boost spring not a return spring.

From my repair documentation:

REPLACED BROKEN CLUTCH BOOST SPRING
1 996-423-081-20 AS SERVO SPRING $79.59

There was labor costs too, obviously. But that's the part.

In my case, the pedal felt mushy and I noticed that the cruise control wouldn't engage unless I pulled the pedal back up with my foot.

 

Not sure what the 996 uses, but I had a similar issue on another car. It was the clutch master cylinder. If you're loosing pressure, it has to be somewhere in the mechanism which connects your foot to the clutch. Most cars use a master/slave cylinder set-up with a hydraulic clutch.

 

Thanks for all of the input folks. Dropped it off at the local Porsche dealer in Boise Idaho, they said it for sure is the clutch. Their estimate is $3000 which includes the flywheel. They said they wouldnt do the flywheel if it is not needed then I could take out about $1000. I asked about resurfacing the flywheel, and the explicitly said that they were not allowed to do this as Porsche will not support it. I called Porsche in Fremont and they said the clutch job would have cost $1700 there, and they could resurface the flywheel if it was needed. Just seems odd that a clutch would just go. No signs whatsoever of potential failure...

 

Mine went at 30k. I blame the previous owner...

While the clutch is out, you should get the RMS seal checked, and also make sure they update the intermediate shaft bearing. Both of these are trouble items and since they'll be in there anyway it shouldn't add any cost.

 

Might want to buy a clutch and flywheel. I see a lot of people using the Sachs clutch. You might as well do the flywheel if you want a lighter one. Flywheels last a long time so if not, I wouldn't worry too much. Labor is the cost, but I'm sure you could pay about half in parts if you got your own. Maybe try to find an independent Porsche shop to do the install, rates tend to be a little cheaper.

 

light flywheel? it's not that simple and you get no gains really from it aside form noise and annoying daily driveability.

stick with the stock stuff.

 

I am going to go with the OEM replacement parts. I would find a good indi, but not many here in Idaho that are familiar with P-Cars. Unless it has a rifle rack and four wheel drive, they just dont work on it.

I am going to have them to the RMS and globerknockle or whatever the hell they called it. They claim its another $400 if they take the fly wheel off, $500 if they dont.

These guys are a rip off, but my only other option is to tow it to California.

This guy got all pissy at me becuase I called Porsche in Fremont and told him his Idaho price is higer than california. He called BS on me and said that every dealer in the country would charge over $2000 for the clutch assembly job alone. Basically said I was stupid and that Anyone who is lower is low-balling me to get me in the door.

I guess this is the price you pay if you want to play with exotic sports cars. Between the 60K service, tires, and this platnum clutch job it puts me over $4500 invested into the well being of the beast. Someday, I want to put some exhaust on this thing but I keep getting soaked by issues....

Oh well, good think I love this car.

 

Skip replacing the release lever at your own peril.

 

I am pretty sure they are doing the release lever as part of the whole deal.

 

Damn, that sucks, too bad you didn't have more resources. That dealership pretty much knows they are the only ones who can do the work near you. I'd still check some resources on the board, you might be able to get a better rate on the OEM stuff. They will mark it up if you go through them. Or maybe ask them if they can give you close to at cost on the parts. They sound like a-holes but if there is a guy in there with business sense (most likely the service manager) he will probably be able to work with you. You're bringing him a pretty big ticket, they should help you out a little.