924Board.org

[timstar92404]

I'm just wondering how much it would cost to replace the clutch at a shop.

the clutch disk, friction plate and release bearing together cost about 400-500 and I'm guessing the labour is going to be alot of hours.

I'm just asking because I have a very heavy clutch pedal (new clutch cable) and i heard that means your clutch is on its way out.

also from haynes instructions on adjustment of the clutch lever, the distance between the clutch lever and bracket has to be 138 +2 +/- witout freeplay. but mine when you pull the lever up all the way the distance is much greater like 10 centimeter greater than the 138 mm.

does this also mean something is wrong with the clutch?

my peddle is so heavy that my leg gets soar and too tired when driving in stop and go traffic, my feet hurts so I have to leave it in neutral at the light.

I read the clutch removal instruction in haynes and its too complicated for me to try, you need to lift the engine with a hoist and make a special wooden support thing and you have to pull the entire transmisson and torque tube back to remove the clutch.
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78 924 sold.
85.5 944

[WhoDak]

[Mike924]

I think the Haynes manual is very confusing on the question of clutch adjustment.

I've come to the conclusion that what they're going on about is two separate adjustments - one for the the angle of the clutch throw-out arm lever and one of the cable free-play.

The 138 mm adjustment, I think, is to get the throw-out arm lever in the right place and then, having got that correct, you adjust the end of the cable to get the right (20 - 25 mm) free-play at the pedal.

Likewise, the 138 mm dimension on my car is too big (probably by about 10 cms) and the clutch is on the heavy side. I haven't done anything about it because it looks very difficult to get the pinch bolt on the throw-out arm lever pivot.
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1985 Porsche 924 'Lux', Kalahari Beige (my ex)
1993 Porsche 968 Coupe, Midnight Blue, 6 spd

'There is no substitute for a little grease under your fingernails.' - Chrenan, 924board.org

[timstar92404]

yeah I think haynes has crappy instructions and pictures. I often have to figure things out myself and then I realize what haynes meant but when I don't know how to do something haynes doesn't help much

this is the first car I've driven that is a manual and when I got it the clutch pedal was sticking and made squeeking noises and was very heavy. the previous owner told me to check the hydraulic fluid.....but obviously the NA does not have a hydraulic clutch.

so I replaced the clutch cable and it got a tiny bit lighter and stopped getting stuck and making noise but now its a bit heavier since changing it last year and you can compare it to one of those stair masters for exercising.

I wear skate shoes which are pretty tough and my left shoe is getting all worn out from driving....
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78 924 sold.
85.5 944

[chris24]

I just bought a new clutch off ebayUK for £40 and am probably going to get a mechanic I know to do it as I just don't have the time at the moment...he's quoted me £200, which probably is mates rates to a degree, but I would get looking for a clutch on ebay maybe...cheaper than paying the mechanic to buy it for you at £200ish (whatever that is in USD).
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1983 - 924 (185K miles) - not mint
1985 - 924 (148K miles) - mint
1990 - 944S2 cab (52K miles)

[Sebring79]

Timstar,

I'm surprised no one has brought this up yet but you may want to re-check your clutch cable before plunking down the cash for a new clutch.

A lot of people end up kinking or bending the cable when they route it through the firewall. When this happens the cable starts to fray inside it's sleeve making the pedal VERY hard to push in.

This is a very common problem on the 924. I even had it happened to me several years ago when I had my first 924's clutch replaced at the dealer.

[timstar92404]

so I would have to replace the cable again to know ?
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78 924 sold.
85.5 944

[Sebring79]

You should be able to take the cable out and check to see if it moves smoothly inside it's sleeve.

[CBass]

The 924 does have a somewhat heavy clutch compared to some hydraulic clutches.

Get under the car and look through the inspection window. See what's going on in there.
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'81 931 in various states of assembly

[WhoDak]

[Mike924]