924Board.org

WhoDak · Joined: 22 Mar 2005 Posts: 492 Location: Akron, OH

Ok, so after an afternoon of cruising around working on a photo project I pull up my driveway, and go to back into the garage. Everything is perfectly fine at this point, no problems whatsoever. I back into the garage, am a little off so I go to pull forward and back again.

This is where it gets ugly. I put it in first, and hear a very slight grind, ease off the clutch and move the car forward out of the garage a bit. Go to shift into reverse and it grinds like I was trying to shift into reverse without the clutch pedal down

. I try to go into first and it reluctantly does with a bit of grinding and it sort of moves the car forward without me releasing the clutch pedal like it was slipping. I move the car forward just a bit and try reverse again, still no luck, I try the other gears and they go in, but a bit funky.

From worst, to easiest:

R
1
2
3
4
5

(edit) Also when the car is off it shifts into gears just fine, so it's not the transaxle.

Any ideas on what just happened? I'm really hoping it's not what I know it is

.
_________________
Mike
'82 924 N/A
'91 Toyota Pickup SR5 4x4 Xtra cab

Lizard · Posted: Fri Apr 21, 2006 10:50 am Post subject:

clutch is out of adjustment it sounds like or the firewall just broke and started to flex too much
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3 928s,

Ozzie · Posted: Fri Apr 21, 2006 10:51 am Post subject:

Clutch is faulty.
Whether it is the clutch itself, the cable or hydraulics depends on the type of setup you have.
_________________
Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance

Lizard · Posted: Fri Apr 21, 2006 10:53 am Post subject:

PORSCHEV · Posted: Fri Apr 21, 2006 11:10 am Post subject:

It's not your clutch......when your clutch goes you get slipping when under a load or taking off. You just have to loof at your adjustment like lizard stated.
_________________
1976 924
5 lug conversion, 17'C2 wheels,custom body work,327 vette engine.

1978-#53 "D" track racer.

WhoDak · Joined: 22 Mar 2005 Posts: 492 Location: Akron, OH

Hmm well I really hope it's just the adjustment, I don't have the time, skill, or money to get it replaced with. I'll check the adjustment per Haynes tomorow. It just seems odd that it happened all of the sudden.
_________________
Mike
'82 924 N/A
'91 Toyota Pickup SR5 4x4 Xtra cab

D Hook · Joined: 02 Nov 2002 Posts: 3158 Location: Omaha, NE

Cable stretched suddenly? Or the end of the cable is about ready to let go? Hope it's not the firewall.
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'80 924 n/a SOLD

Lizard · Posted: Fri Apr 21, 2006 1:51 pm Post subject:

due to its sudden attack it is either imo a) the clutch arm attached to the fork slipped
or b) the firewall let go.
_________________
3 928s,

WhoDak · Joined: 22 Mar 2005 Posts: 492 Location: Akron, OH

I took a look today and I can't seem to find a decent spot to get my hands or a pair of wrenches in at the clutch adjustment area. I tryed getting a ruler there from underneith and the measurement that I got was about right, 138mm. I say about right, because I couldn't get in there exactly right to read the ruler.

Is there an easy route to get at the cable area?

Also I started the car and it went into first, second, third, fourth, fifth, and even reverse while standing. It did so with a slight bit of grinding and a weird "smooth scraping" sound from the clutch area. It worked well enough to pull out of the garage and back in a few times. During this I had it in reverse and the clutch pedal to the floor and the clutch seemed to 'catch' slightly and ease the car back slowly then it would release and coast to stop.

The only thing I did was turn the top nut on the top bracket of the clutch adjustment about a half turn, and then turned it back because it wasn't undoing the nut, just twisting the cable. Other than that I did nothing but poke around inside the inspection area on the bellhousing. I measured the clutch disc and it was about 10mm so it's within tolerance to my understanding.

I also checked the firewall area from under the hood and I pulled back the cable housing just a bit and the metal looked fine. I don't have anyone to push the clutch for me right now, but the metal looked a-ok.

I'm really pretty lost in the realm of clutches and have been trying to learn a bit about ours in some older posts.

Any advice on where to go next?
_________________
Mike
'82 924 N/A
'91 Toyota Pickup SR5 4x4 Xtra cab

madhatter · Posted: Sat Apr 22, 2006 4:36 am Post subject:

Mike:

Has the pedal pressure or engagement point changed at all since the problem started? Are you sure the slave is not leaking and is holding pressure? I am guessing from your description that you have no leaks in the system and have checked already, but I had to ask since it sounds to me a like a little more than an adjustment problem your having. I have had several Maserati's before that I had the same problem you are describing and in each case it turned out to be a bent clutch fork of all things.....and it actually happens out of nowhere just like your situation. Maybe someone else on the list that has had to replace their clutch fork before can tell you if it's a possible cause in your case.

Steve

WhoDak · Joined: 22 Mar 2005 Posts: 492 Location: Akron, OH

The engagement spot has stayed the same, it's always seemed slightly high compared to my truck, in my truck it catches pretty close to the floor so it's not an accurate comparison. There haven't been any fluid losses from the master or slave cylinder. If the clutch needs to come out for it to be repaired, I will be selling the car with it's current problem.
_________________
Mike
'82 924 N/A
'91 Toyota Pickup SR5 4x4 Xtra cab

PORSCHEV · Posted: Sat Apr 22, 2006 8:48 am Post subject:

You got me confused if your checking your master and slave cylinder...you shouldn't have that except for brakes!

If I recall correctly you can adjust the cable length in 3 locations.... under the dash on the end of the cable( not an easy spot) at the firewall location and the splined pivot point. beofre i went too deep I would tighten the cable up and see if that does it. Thats where I would put my money. You can't hurt anything by doing so and it would rule out that being a potential problem.
_________________
1976 924
5 lug conversion, 17'C2 wheels,custom body work,327 vette engine.

1978-#53 "D" track racer.

Benino · Posted: Sat Apr 22, 2006 8:51 am Post subject:

This being a 1982 N/A it has no hydraulic clutch system. Just a cable clutch. right? I haven't had to adjust mine at all lint he last 5 years. I can't remember how the arm that gets pulled by the clutch is attached to part that goes into the bell housing? Is it splined? Does it just go on one way? What I would do is try my best to get pliers or wrenches or whatever in there so that you can turn the adjusting nut screw to tighten the clutch cable. Adjust it until the clutch works correctly. Make sure that the nut is tight again once you are done adjusting. If you can't adjust enough to get the clutch to engage well, then I'd guess that the arm stripped the splints on the part that goes into the bell housing. I believe that arm can be taken off of the rod that goes into the bell housing. Make sure that it is completely on and not starting to fall off.

Has anyone here had a clutch fork break on a 924 N/A? I would think the cable would break before that could happen.
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1980 Porsche 924 N/A USA
1980 Porsche 924 turbo USA
1987 Porsche 944S USA

madhatter · Posted: Sat Apr 22, 2006 10:31 am Post subject:

I forgot the 924 does not use the hydraulic system of the 944 duh!, so no worries there....the fork does not break, but will bend and deform just like a spoon would if you tried to bend it in half, making it difficult to engage the gears cleanly. But, I believe the other adjustment posts should help you fix it if it's just an adjustment that is really needed.

Steve

timstar92404 · Joined: 22 Sep 2004 Posts: 2075 Location: richmond BC

isn't it strange why they would use plastic to connect the cable to the pedal...

anyways could be your cable, just make the distance between the lever and the clutch bracket or whatever its called smaller and see if it will stop grinding...... haynes has a picture to show the correct distance.
_________________
78 924 sold.
85.5 944