Removing and installing the clutch pedal
Removing and installing the clutch pedal
Information
^ Important notes
^ The description below applies to left-hand drive vehicles.
^ On right-hand drive vehicles, the clutch pedal lever is located directly next to the brake pedal (separated by the steering outer tube in the case of left-hand drive vehicles). Assembly/disassembly for right-hand drive vehicles is similar to the procedure for left-hand drive vehicles.
^ Before the start of disassembly work on the pedals, the clutch boost spring must be fixed with a cotter pin (arrow at No. 5).
^ Important: secure the cotter pin (bend it over).
A - Clutch pedal area
B - Brake pedal area
Notes on removal and installation
Removal
Warning
Danger of injury and / or damage during disassembly and assembly work! The clutch boost spring can become detached on its own.
-> Before the start of disassembly work in the area of the clutch pedal lever (exception: clutch pedal switch), the clutch boost spring must be fixed with a cotter pin (Figure 478_98)
1. Disconnect battery ground cable.
2. Remove driver's seat (to facilitate work).
3. Remove air duct (A). The air duct is plugged in.
4. Detach diagnostic socket.
5. Detach relay carrier, unclip and lower into the footwell.
6. Release clutch pedal switch by turning it 90° and pull it out of the installation opening.
7. There is an assembly bore in the guide rod for the clutch boost spring. Insert a 3 mm [diameter] cotter pin in this bore, and bend over the ends (securing: refer to Figure 478_98).
8. Remove pin between the clutch push rod and clutch pedal lever.
9. Remove retainer (1) on the pedal bearing axle.
A - Clutch pedal lever
B - Brake pedal
C - Steering outer tube
X - Bearing bushings
1 - Retainer
10. Undo fastening nuts from boost spring bracket (arrows). Requirement: Boost spring secured with a cotter pin. Remove clutch pedal lever together with boost spring and bracket.
Installation
1. Inspect all bearing bushings X for clutch pedal lever and replace them if necessary. Lubricate sliding surfaces of the bearing bushings X (Figure 466_98) and the pedal bearing axle with Optimol, Optitemp LG 2, Part No. 000.043.203.37.
2. Assemble boost spring, bracket and clutch pedal lever. Description under step 2.1 or 2.2.
2.1 Carrera (996) Mod. '98 / some Mod. '99
2.2 Carrera (996) from current Mod. '99
Information
^ In the 911 Carrera (996), different boost springs maybe fitted.
^ Observe proper allocation when replacing the boost spring and/or the bracket.
A modified (optimized) clutch pedal must also be sometimes be using when replacing the boost spring.
Greasing of the boost spring bearing points is partly necessary and partly not permitted (depending upon the type of boost spring used).
2.1 Carrera (996) Mod. '98 / some Mod. '99
Identification/differentiation:
Push rod of boost spring open on one side, boost spring parts not coated.
Grease pin for boost spring (arrow) with mating bearing on the boost spring push rod, the boost spring bearing (arrows) and the bearing pins on the boost spring with Optimol, Optitemp LG 2, part No. 000.043.203.37.
Greasing necessary (arrows)
First remove old grease with solvent naphtha.
2.2 Carrera (996) from current Mod. '99
Identification/differentiation:
Push rod closed / boost spring parts coated.
The date of introduction for this boost spring is contained in the Parts Catalogue.
Engage the hexagon bolt of the boost spring in the hexagon on the clutch pedal (arrow).
Danger
Do not grease, as the sliding surfaces of this type of boost spring are coated.
-> This non-greasing instruction applies to all sliding surfaces (pin of boost spring, boost spring bearing in bracket, bearing pin on boost spring and boost spring in the shell).
Do not grease (not permitted)
Information
^ Gold-colored bracket (996.423.571. 00) and boost spring with purple marking (996.423.081.09 Mod. '98 some Mod. '99 or 996.423.081. 11 from current Mod. '99) must be used only in this combination and installed only in the 911 Carrera (996).
3. Installation and adjustment specification for boost spring bracket. Install preassembled boost spring bracket with clutch pedal lever.
To do this:
Step 1:
Tighten the three fastening nuts (arrows) only slightly (the bracket must still be movable).
Step 2:
Tighten the clutch master cylinder to 10 Nm (7.5 ftlb.) (if the clutch master cylinder was detached).
Step 3:
Press the clutch pedal against the direction of travel until the pull stop in the clutch master cylinder is reached.
Step 4:
Remove cotter pin (retaining pin) on the spring cup so that the clutch pedal is pressed against the rubber stop in the boost spring bracket.
Step 5:
The bracket is screwed down with the clutch pedal pressed back (to make full use of the slots).
Tighten hexagon nuts (arrows) in the prescribed sequence.
Tightening torque: 7.5 Nm (5.5 ftlb.).
Sequence: 5a / 5b / 5c
Information
^ The push rod of the clutch save cylinder should not be lubricated in general (for all versions).
4. Fit new retainer on the pedal bearing axle and subsequently secure the retainer by wedging it with a mandrel.
5. Install clutch pedal switch. First pull operating plunger out of the switch as far as it will go. By means of its self-adjustment function, the switch then compensates for tolerances in the pedals.
6. Check the interlock switch adjustment on vehicles with interlock.
Adjustment specification for interlock switch:
The switch must be aligned so that, with the clutch pedal depressed, it is operated approx. 1 to max. 2 mm before the limit stop of the clutch slave cylinder is reached.
7. Install relay carrier, diagnostic socket and air duct.
8. Perform a function test on clutch and brake operation.