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Clutch pedal - metallic click

MeltonMowbray

Trainee
Joined
7 Nov 2021
Messages
57
Hi all - I know the clutch has a switch at the BOTTOM of the travel, but my car has developed a metallic sounding click at the top of the travel.

It's about an inch down - when the pedal resistance steps up - there is the click which is audible and can be felt a little in my foot when this increased resistance is first overcome. The clutch operates fine and I've not had any other issues.

I've had a look in to the pedal area and can't see anything obvious or loose.

Any ideas? I can put it in to the shop but seems a bit of a vague request so trying to do some diligence first.[/list]
 
There is a clutch assist spring attached to the pedal mechanism. You'll find some details on Alex's thread here: http://911uk.com/viewtopic.php?t=148455

You can find more on Rennlist, where it seems quite common for American owners to remove the spring for better pedal feel. The diagram in the 1st link below gives you an idea where to find it, note you'll need to push a rod/screw/something into the hole at the end before you remove it, to ensure the spring doesn't fly out.

https://www.renntech.org/topic/33177-broken-clutch-power-spring/
https://members.rennlist.com/jandreas/Clutch Pedal Noise.pdf

You might want to experiment with removing it, it's relatively easy, the main challenge is due to the position & having to contort yourself in the footwell.

Ian (DeMort) eventually found that re-greasing the pedal mechanism helped to address the issues I had.
 
sp1ke said:
There is a clutch assist spring attached to the pedal mechanism. You'll find some details on Alex's thread here: http://911uk.com/viewtopic.php?t=148455

You can find more on Rennlist, where it seems quite common for American owners to remove the spring for better pedal feel. The diagram in the 1st link below gives you an idea where to find it, note you'll need to push a rod/screw/something into the hole at the end before you remove it, to ensure the spring doesn't fly out.

https://www.renntech.org/topic/33177-broken-clutch-power-spring/
https://members.rennlist.com/jandreas/Clutch Pedal Noise.pdf

You might want to experiment with removing it, it's relatively easy, the main challenge is due to the position & having to contort yourself in the footwell.

Ian (DeMort) eventually found that re-greasing the pedal mechanism helped to address the issues I had.

I may well owe you a pint (or alternative beverage of your choice) - the pictures black cylinder thing is about the only item I could see that could have been contributing to the noise (very difficult to press clutch while you've got your head in there). I had done some digging on Rennlist and was beginning to find a few spring related posts so you've saved me a load of time here.

Let me investigate a bit more when I get a chance to look at it again. Is it hard to remove? I've seen a few warnings about pre-loading the spring to stop it exploding - looks like you managed to pin your one easily. Is it spannerable for a relative novice or am I at risk of making a mess?
 
you're welcome, happy to be able to help :)

The 1st link below has a diagram & some steps. I'd imagine the process is much the same for a 996 or 997. It's not too difficult to remove, but it'll help if you have a smaller build, are supple & able to lie on your back in the footwell. You'll need to remove 2x ducts that feed the air vents. This should give you access to remove the spring. be sure to use a pin, screw or something in the end to retain the spring in the housing. From memory, you'll need to angle it downwards to wiggle it out from the mechanism.

https://rennlist.com/forums/996-forum/343297-improved-clutch-action-dramatically-2.html

https://www.renntech.org/topic/13367-clutch-booster-spring-removal/

As I mentioned below, I think Ian (@DeMort) fixed my issue by applying some grease somewhere a little higher up the pedal mechanism. I should think this would be possible without removing the spring, so you might want to try this before removing it.
 
sp1ke said:
you're welcome, happy to be able to help :)

The 1st link below has a diagram & some steps. I'd imagine the process is much the same for a 996 or 997. It's not too difficult to remove, but it'll help if you have a smaller build, are supple & able to lie on your back in the footwell. You'll need to remove 2x ducts that feed the air vents. This should give you access to remove the spring. be sure to use a pin, screw or something in the end to retain the spring in the housing. From memory, you'll need to angle it downwards to wiggle it out from the mechanism.

https://rennlist.com/forums/996-forum/343297-improved-clutch-action-dramatically-2.html

https://www.renntech.org/topic/13367-clutch-booster-spring-removal/

As I mentioned below, I think Ian (@DeMort) fixed my issue by applying some grease somewhere a little higher up the pedal mechanism. I should think this would be possible without removing the spring, so you might want to try this before removing it.

Thanks for the links - I've been doing som homework as well. Think I might give this a go myself.

The one thing that is unclear is where the pin or screw goes to keep the spring compressed? I was thinking the process was this:

1. Press clutch in (broom trick)
2. Pin the spring (where does this go?)
3. Undo the one (?) bolt that is holding it in place (part 8 in the bigger schematics posted)
4. The whole drum falls off, then presumably decompress the spring with a vice or similar to then store / investigate

Appreciate any insight you have on points 2/3 in particular above. I had a look on YouTube but couldn't find anything!
 
If there's any pints going, I'll have one :viking:
 
Alex said:
If there's any pints going, I'll have one :viking:

The more the merrier!

Is it a case of popping a pin in the hole pictures here then press the clutch until the spring is unloaded - so the length in the pic you have in your thread?

lWcl7Fv.jpg


Porsche guidance is not to lubricate - I'm half tempted to get some silicon spray in there to see if that cures it....
 
Yes you put a split pin in that hole , that will lock it .

N0 you don't use a broom handle to depress the clutch pedal .. it slips and your in hospital .. you have to use a hand to depress ..

There is a pin in the clutch pedal that needs removing and the spring sits on a bracket each side ..

I would class this as a 5/10 diy job .. its fiddly and if your on the larger side then forget it as access is a pain .

Worst way for you .. you get it off and can't refit .. you can still drive the car with a heavy pedal to a garage .

For me .. hmm .. a can of spray grease and spray up inside the booster spring then work the pedal many times :)

I'll see if i can find replacement instructions .. brb .


EDIT for images ..
 

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deMort said:
Yes you put a split pin in that hole , that will lock it .

N0 you don't use a broom handle to depress the clutch pedal .. it slips and your in hospital .. you have to use a hand to depress ..

There is a pin in the clutch pedal that needs removing and the spring sits on a bracket each side ..

I would class this as a 5/10 diy job .. its fiddly and if your on the larger side then forget it as access is a pain .

Worst way for you .. you get it off and can't refit .. you can still drive the car with a heavy pedal to a garage .

For me .. hmm .. a can of spray grease and spray up inside the booster spring then work the pedal many times :)

I'll see if i can find replacement instructions .. brb .

Thanks deMort!

I'm relatively small so access likely as good as it can be. Still pretty uncomfortable though. Agreed on the broom handle I managed to press the clutch by hand so will do that or rope in a helper.

Looking at this 996 video it looks like the spring is unloaded at the top when clutch is not pressed.

https://youtu.be/YfjD4a_m900

I can see the bolt that needs undone and also where the split pin goes. Last bit is understanding how to have the clutch pedal / spring length wise when undoing. Presumably doing it when loaded would be a grave error!

Spray grease is sounding appealing - I'm just wanting the noise to go in relatively happy with clutch etc other than that rattle / metallic noise at the 1" mark.
 
Images have been added to my last post .. a mixture of 996 / 997 .

You have to depress and hold the pedal down whilst removing and refitting the booster spring .

That's the headache to be honest .

look at booster spring when you depress .. there is a sweet spot to fit the pin .

I would start with a can of spray grease first .. maybe a drop on the side pins of the booster if you can get at them .
 
deMort said:
Images have been added to my last post .. a mixture of 996 / 997 .

You have to depress and hold the pedal down whilst removing and refitting the booster spring .

That's the headache to be honest .

look at booster spring when you depress .. there is a sweet spot to fit the pin .

I would start with a can of spray grease first .. maybe a drop on the side pins of the booster if you can get at them .

Thanks for the pictures - they are really helpful! I've just gone in for a proper look around with a bit of knowledge.

I am wondering now if the noise is actually a creak from the connection behind the pedal that goes through the bulkhead - think this might be the connection to the master cylinder or similar?

Can this be greased? I have some pictures and a short video i can try get online

Video here - noise seems way louder on the phone but you can hear the click:

EDIT: In a plot twist, after greasing a few of the bolts I admitted defeat and took the car to run an errand and it seems to have either cured or partially cured the noise. It was still making it when testing while stationary, but maybe just needed a run out to bed the grease in.

The bolts I did were the assist spring bolt, the one attaching the above pictured bit to the clutch pedal and also up at the clutch pedal pivot itself. I think the latter might be the one that made the most difference and also the most awkward to get to. If it's only a partial fix I might go back and a bit more there first.
 

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The noise to me sounds like the pivot joint from the clutch master cylinder in the pedal or the side pivots of the booster spring ..

After a bit of digging i came across a tech bulletin about noises which refers to the instructions for clutch pedal removal ..

Download and have a look as halfway down it says where to lubricate ..

https://drive.google.com/file/d/1Y6KTTxF4A8cfJm6_5Q-q1zYTVMKTfvLu/view?usp=sharing

My link so safe .

Rule of thumb .. press the pedal and see what moves .. spray these areas whilst moving the pedal .. after finished then operate the pedal many times to work the grease in .

Sounds like you are getting there anyways :thumb:
 

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