Figuring out how to change a clutch on a Porsche 944 is a big job which is quite labor intensive. But keeping your classic in working order is worth it. Here's a quick run down of how to do it:
- What You'll Need:
- Slide Hammer
- Wrench Set
- Chock the rear wheels, select Park and apply the handbrake. Remove the negative battery lead.
- Jack the car up. You'll need at least eighteen inches of room to remove ignition sensors on top of the bell-housing.
- Remove the exhaust system, applying penetrating fluid to any rusted bolts.
- From inside the car, remove the gear shifter boot, gear shifter handle and the cir-clip holding the rod to the lever.
- Remove the trans-axle or prop shaft by undoing the bolts and sliding it out of the direction of the drive-train.
- Disconnect the reverse light switch, electronic speed sensor and the CV joints at each end of the drive-shaft.
- Undo the coupling collar's two bolts and shift rod from the gearbox casing.
- Support the trans-axle with the jack. Lift it up slightly, which will take the weight, remove the two trans-axle hangar bolts and it will enable you to remove it from the bell-housing and the prop shaft. The engine may need to be raised slightly to help jiggle the trans-axle out.
- Remove the starter motor and clutch slave cylinder, by removing the bolts and sliding out of their respective apertures.
- Remove the dust cover and the clutch release arm shaft which it covers. Use a slide-hammer to release the shaft.
- Remove the six bell-housing bolts which attach the gearbox to the engine. Four of the six are easy, but the other two might need heating with a propane torch or penetrating liquid.
- With the bell-housing detracted you can remove the clutch plates, clutch cover and release bearing. They are removed by undoing the mounting bolts. The starter/timing gear ring needs to be tapped to help release the used clutch plate.
- Replacement is the opposite of removal. Remember to fit all of the wiring, new bolts if you have to put excess strain on them and use a clutch alignment tool, which will save you having to take it all apart if you get nasty clunks in the drive-train.
To reassemble, follow retrace the steps and make sure you don't have any parts left over.
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