I think is time for a new clutch.

After 4 years of faithful service and 47K miles, my MY99 (04/98) 996 needs a new clutch...or so I think, due to some slippage in third and fourth gears during 0-100 mph runs. Any idea on a good shop in Northern/Central Cali that is trustworthy? I think I am looking at about $2k, correct? I know CarlosR had his done. Any feedback would be greaytly appreciated. TIA. -Freddy

WELCOME!

Hello Don and Thanks! <img src="graemlins/xyxwave.gif" border="0" alt="[bigbye]" /> Nice to see you here...then again from looking at your profile, you've been here for a while. I like it here... -Freddy

Hi Pauli, Well i've posted two messages with little feedback really.. not that i'm happy that you have the same problem, but at least I can also share with you the issue.. Being in nigeria, things are much harder here to solve. Funny enough the mechanic just came out now with the car key and the new clutch kit (disc, plate and bearing) that I got from Dubai. The whole thing started with smoke from the engine which i thought was the brakes since it was only coming after hard driving (i thought it was due to the ABS working with the T/C).. Then the slippage started to get more evident, 5th, 4th, 3rd, then last 2nd gear.. It just revs up without really moving and then catches later over the 4k rpm range.. Then I started noticing in my mirror a white 'puff' of smoke at every slippage especially at high speeds.. I'm really afraid that there is oil leakage in the clutch housing. I've also gotten from Porsche dubai diagram printouts of how to dismantle the clutch which is easy they told me.. I will fix the leaking engine seals as well (very common in 996 i learn from listers) I'm crossing my fingers here and hope things will turn out well.. Wael 996 C2 1999 A.silver 6sp 928 S 1984 G.Red Aut

Sounds to me more like the rear main is leeky and has coated and glazed both the pressure plate, clutch and flywheel! If so replacing the clutch will not cure the problem. I am stating this because of the white smoke issue. Might just be the clutch though. Does it only slip after it heats up a while? If so that is more indicative of a leaky rear main, which pukes onto the clutch. Then again, it would most probably slip more on the lower gears. Interested to find out what the culprit is. also, you always want to replace the throw out bearing when doing a clutch replacement. I don't know if it's hydrolic, but it's always a good thing to do, it will make it smoother to engage as well, depending on your milage and wear.

SPR, What do you mean by rear main?? Suppose it is the cause, is is a standard bearing part or is it an exclusive porsche part? TO answer your questions: - The car used to slip on cold temperature and catch on later when the engine heated.. now it's slipping hot&cold at all gears except 1st (after about one month of noticing it) Once it slips, it catches later on the same gear, but slips again on the next gear, and so on! - It started slipping on higher gears rather than on lower ones; never slipped on first! - What is a throw bearing? I received a third part (together with a new clutch and a new plate) that looks like a bearing i suppose, that is 2~3inch in diameter, 2inches long, made of combined plastic&steel. Is this it? - My mileage is 68,000km (42,000 miles) and the shift is very responsive and never gotten problems shifting

To Answer Ferddy (and not Pauli!): the clutch kit cost about $500 (after a generous discount due to an offer they give you if you buy the whole kit and not the disc only, otherwise it's about $800).. Labour here is going to cost me about $200..

Waz, My syptoms are similar to yours except for the smoke. I am noticing more of the slippage in 5th, 4th and now 3rd gear. Unfortunately( or fortunately), I don't get any smoke or any smell of anything burning. I do feel the slippage. You have to be careful with the Rear Main Seal (RMS). If you think the RMS is failing, like it has been mentioned before, could lead to more problems in the future. I would get that taken care off immediately. Good luck (to both of us). -Freddy

Excuse my ignorance, what is a rear main seal? i understand it's a seal ok.. but where? And why did it happen? my oil pressure is normal, ranging from 1 to less than 5 over the rpm range when the engine heats up.. Is it a standard size seal i can get like from aftermarket parts manufacturer (if yes, what is recommended?) or is it an exclusive porsche part? Is changing it a tough job? something like i'll have to dismantle the engine, top cylinder, pistons, cams, crankshaft..? Wael (now I'm worried! )

I emailed you a detailed response. I like the monkey signature, btw. hehe

Ok guys, let's see what tomorrow will bring. Expect the worse and carry on with life... Wael <img src="graemlins/icon501.gif" border="0" alt="[icon501]" />

OK, I just sneeked from work and checked the car.. unfortunately he hasnt done anything except to lift it up.. Now it's evident that there is a leakage of oil in between the transmission and the engine. This means there's a 90% chance of a rear seal leak.. Mechanic says he doesnt find the problem in changing that and that I shouldnt be worried.. He even showed me the same problem of a 964 he is repairing now.. More updates tomorrow.. wael

You may want to try Tim Benson at Fast Lane in Santa Cruz. He worked for My Porsche in Seaside and opened his own shop a few months ago. Before that he worked at Anderson - Behel Porsche in San Jose. Jeff

Distance between Santa Cruz, California, United States and Lagos, Nigeria, as the crow flies: 7800 miles (12553 km) (6778 nautical miles) Initial heading from Santa Cruz to Lagos: east-northeast (61.7 degrees) Initial heading from Lagos to Santa Cruz: northwest (314.8 degrees) See airfares between these two cities in Expedia or Travelocity. See hotels in these two cities in Expedia or Travelocity. See driving distance and directions (courtesy MapBlast). See these places on the map (courtesy Xerox PARC). Santa Cruz, California, US County: Santa Cruz County Location: 36:58:24N 122:02:09W Population (1990): 49040 Elevation: 20 feet Lagos, Nigeria Location: 6:34:59N 3:01:59E Wael (now you know.. <img src="graemlins/crying.gif" border="0" alt="[crying]" /> )

Freddy, This could be closer to you.. (lucky guy!) Wael

[quote]Originally posted by Waz996: <strong>Distance between Santa Cruz, California, United States and Lagos, Nigeria, as the crow flies: 7800 miles (12553 km) (6778 nautical miles) </strong><hr></blockquote> <img src="graemlins/roflmao.gif" border="0" alt="[hiha]" /> <img src="graemlins/roflmao.gif" border="0" alt="[hiha]" /> <img src="graemlins/roflmao.gif" border="0" alt="[hiha]" />

Waz, ...you crack me up! <img src="graemlins/roflmao.gif" border="0" alt="[hiha]" /> I am interested to see how everything turns out. Jeff, Thanks for the info. I'll check them out! -Freddy

[quote]Originally posted by Waz996: <strong> Now it's evident that there is a leakage of oil in between the transmission and the engine. This means there's a 90% chance of a rear seal leak.. Mechanic says he doesnt find the problem in changing that and that I shouldnt be worried.. He even showed me the same problem of a 964 he is repairing now.. </strong><hr></blockquote> Certainly sounds like it! Yes, relatively easy to replace the seal. BUT ... to give you sleepless nights, let me also point out to you that there are usually four potential reasons for this failing: 1) Age -- the seal becomes brittle and doesn't flex anymore (not likely given the age of your car but possible given the heat in Nigeria). 2) Wear from dirt and other grime. 3) Machining errors on the case and/or crank shaft which means that the crank shaft is not properly centred in the oil seal. 4) Defective seal. There have been a few cases reported here where oil leaks have not been solved by replacing the seals and Porsche has ultimately replaced the engine under warranty. Problem #3 was likely the cause of this. S.

Thanks for the info FixedWing but replacing an engine here might be a bit too impossible! Hey freddy! I wish you never started this board! lol!! Now am crossing fingers, hands, legs and all paired members I got over here!!! Wael <img src="graemlins/jumper.gif" border="0" alt="[jumper]" /> <img src="graemlins/c.gif" border="0" alt="[ouch]" />

Sorry Wael <img src="graemlins/icon107.gif" border="0" alt="[icon107]" /> Wasn't my intention.. But think of it this way...better now than when the car is out of warranty Good luck.

Freddy (..and all interested), Sorry i forgot my digicam in my office otherwise i have taken some pictures about my c2 clutch.. The mechanic was able to dismantle the Gear/Differential unit AND NOT THE ENGINE. It is a lot easier this way. There's only one electric wire (should be the T/C control) and no vaccum, electric, oil or any other hoses/wire plugged.. very basic. Results: 1-the clutch disc is wiped off! Barely any more thickness in it. Actually it is on the metal from the Clutch plate side. Lucky me I got a new clutch plate and disc. Lucky me even more that the Flywheel side of the clutch still has some thickness and hasnt even scratched the flywheel which is still shining and clean. But i will take it to precision shop to make a shining run on it. The clutch bearing will also be changed. 2-The clutch plate and the clutch disc has no sign of any oil, they are dry BUT.... 3-There was an evident leak of oil from the rear main seal (now i know what it is!) localized behind the flywheel. The oil has not dissipated to the clutch disc and plate but still I have to change the seal NEXT ACTION: get a local main seal (SASH or similar approved brand of same size). I have also contacted Dubai to check out from dealer there and send it courrier to me.. whichever comes first. Wael (the HoRrOr is still on.. ) 996 C2 1999 (hang on baby, you'll make it!)

Freddy, Seal ordered from dubai, $17 + $25 Courrier. Will arrive max one week. Meanwhile i'm polishing the flywheel, replacing brake warning cables and trying to fix all other oil leakages from bottom and side engine covers.. I hope the engine seals of the 98 and 99 models are the same coz they might have sent me the 98 model's own.. but i learnt that 98-01 engines are all the same? figure that out, sherlock! <img src="graemlins/c.gif" border="0" alt="[ouch]" /> Wael

Hi Fred, This is the dismantled clutch and the seal picture. The oil was already cleaned in this picture that is why it doesnt show.. Wifey calling at the door, byyyyyee Wael

Wael... You are the coolest!! Thanks for the awesome pictures. I am actually having the clutch replaced. No Flywheel damage thank God, no leaks. Cost for parts and labor quoted at $1200 from a dealer. Thanks again for the pics. We all apreciate them. Keep them coming. <img src="graemlins/beerchug.gif" border="0" alt="[cheers]" />

Hi Freddy, Glad your clutch repair is going as planned.. As Loren said, do check for your engine seal, else you'd be throwing your new clutch down the drain.. Last but not least and especially for a guy like me in the real wildreness, i couldnt have done anything without the help of you and all the rennlisters there, thank you guys.. Wael

Hi Freddy, Hi all! Finally! after receiving the clutch disc and plate, bearing and rear engine seal. The car was assembled back today and ran perfectly well.. The clutch now is much smoother than before. Moreover, the performance has gone to an impressive standard. I didnt know I was missing so much torque when the clutch was really slipping. The engine rear seal replacement was very easy. THe oil leaks are now all repaired. The only problem is that the clutch pedal has a very big gap now. As if the system is filled with air. While the clutch engages at very low pedal, it just stops halfway and there comes the gap. I stopped the car after bringing it back home, pumped the clutch several times quickly and the gap shortened almost faded.. I dont know if this is a plate problem or an air-in-the-system problem. I dont know if the gap will return. The mechanic said i should allow it a couple of days. I will surely solve it, but the hardship is now over. The car lives again! Last but not least, thanks for all the listers on the forum and to Fadz roaming somewhere around Dubai for sending me all the parts! Wael 996 C2 99