Why is my clutch so heavy?

The first time I sat in my 996 and did the usual exploratory press on the pedals I remember thinking "bloody hell the clutch is heavy!". Meanwhile I've seen numerous examples of people who've done their clutch and been amazed at how light the newly-refurbished clutch action is. It seems like something that can change imperceptibly over time and you only notice when there is a step-change of a replacement or trying out someone else's car. My car was daily driven and now has 203,000km on it, the clutch and DMF were changed at the dealer sometime around 100,000km. It does not slip in normal driving (even to redline in 2nd & 3rd) but the one time I have tried an enthusiastic launch with 4-5krpm I felt the pedal was all the way out and the clutch did not fully 'bite' for a short while. Clearly it will be no luxury to replace it and I need to do the rms anyway. So I'm curious what actually makes the clutch so heavy? The only variables I can see are: * Spring tension - a worn plate will reduce spring preload, and old sagged springs will produce less pressure rather than more?? * Friction - Hydraulic actuation so should be no issue there. Throwout bearing worn (how does this make it heavier?). Friction of plate on spline (maybe, but seems unlikely). * Lever geometry - as the plate wears, the geometry of the throwout fork leverage changes? Anyway, just some musings as to why it gets heavier, since simple wear/age of plate or spring would suggest it getting lighter. On to more useful questions, I'll be DIY'ing this job and ordering parts in ahead of time, so want to cover what I am likely to need. So I have this list: 996 116 911 02 Clutch kit 1 SACHS 996 114 012 05 Dual mass flywheel 1 LUK 0PB105249 Rear main seal 1 GEN 999 073 092 02 Flywheel bolts 8 GEN 9A700407600 Pressure plate bolts 6 GEN 997 116 712 01 Clutch Release Lever 1 GEN 012141751C Pivot Piece for Release Lever 1 GEN 996 116 716 02 Ball Pin for Release Lever 1 GEN 9P1141181 Guide Tube for throwqout brg 1 GEN 9P1141143 Sealing Washer for Release Lever 1 GEN 9P1141164 Retaining Spring for Release Lever 1 GEN It seems logical that the release lever and associated parts might be worn out, would the more experienced agree it is wise to order all that stuff up front? Is there anything I've missed? I basically got that list from the Pelican 'super kit' for 996 clutch. Thanks in advance

The fingers on the clutch cover go hard through thousands of heat cycles. Thats my take on it.

Have you considered the simple helper spring on the clutch pedal? - I'm fairly sure this has featured in a service bulletin as there were failures in some springs and a more robust replacement part spec'd - if its never been touched this could be something that would degrade over time With the clutch mechanism itself, there was certainly a change to the release lever and its associate spring+washer - there seems to be quite an interval of mileage between your clutch changes - what's the time interval? i.e. that could answer whether your own car has revised parts or not...

Clutch assist spring could have broken and/or the clutch slave cylinder needs replacing both quite common, mine had the assist spring break at 60k miles and the slave cylinder was done earlier this year at 65k miles

As above. Another reason for it getting stiff is all the build up of "brake dust" in there from the clutch plate bunging everything up..

I replaced the helper spring in my old 986, involved various headstand positions in the foot well! Not too difficult but made little difference overall. Stiff pedal seems to be the main sign of a worn clutch on these cars..

As per Parsley,s comment .. clutch cover plate fingers is the main cause .. When a new clutch is fitted it's not unusual to be stamping on the clutch for a while until you get used to it being soft . Booster spring broken is possible but a new clutch usually fixes it .

Had mine clutch changed to Sachs 890nm with slave cylinder and sphere, made all the difference As at was slipping after the Markski map!!

Thanks guys! Shortly after acquiring the car I did do the under-dash acrobatics to have a look at the helper spring. As far as I could see it was working correctly. I was just curious as to why, but it seems the fingers are the main suspect. Sounds sensible, I just hopped in a 944 yesterday and nearly shoved my foot through the firewall the clutch was so light. By 'sphere' do you mean this? With my mileage and age, it's not going to be a bad idea to replace most of the release components.

:grin: I do that every time I jump back in my daily. Try a GT3. I've now got a left leg like Popeye's and a right leg like Olive Oyl's.

[quote="Marky911" :grin: I do that every time I jump back in my daily. Try a GT3. I've now got a left leg like Popeye's and a right leg like Olive Oyl's.[/quote] I'd love to! Your leg asymmetry seems to qualify as a genuine first world problem!

Stewpot67 has a pressure sphere which is only fitted to Turbos and so not applicable to a non Turbo car . You have pictured the release arm pivot .. it's not that

Ok, sorry thought they were on both..

I'm not having a go young man .. just pointing out the difference between different cars .. you keep answering whatever you wish .... please

Lol...liking the young man!! Every day is a school day!