Clutch Replacement – 2.5L NA

Overview

This procedure outlines the steps to replace the clutch on all Porsche 944 variants with an 8-valve engine configuration, covering both Pre-85.5 (1983–1985.5) and 85.5 Onwards (1986–1988) models. The clutch replacement is essential for restoring smooth gear engagement and vehicle performance when the clutch is worn or damaged. This guide is tailored for DIY enthusiasts with mechanical experience, requiring significant time and patience due to the complexity of accessing the clutch assembly. Expect approximately 16 hours of labor for the 944 8-valve engine variants.

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Tools Required

• Metric socket set
• Metric wrench set
• Jack stands
• Floor jack
• Clutch alignment tool (944-specific or metric universal)
• 8mm cheesehead tool (12-point internal)
• 12mm cheesehead tool (12-point internal) (if flywheel is removed)
• Slide hammer bearing puller set
• Various screwdrivers (Phillips and flathead)
• 150mm long, 8mm thread bolt
• Locking pliers
• Hammer
• Molybdenum disulfide grease (MoS2)

Parts Required

• Clutch disc (944 116 027 06)
• Pressure plate (944 116 027 06)
• Release bearing (944 116 080 00)
• Pilot bearing (999 201 079 00)
• Pressure plate bolts (6) (900 067 091 02)
• Flywheel bolts (8) (if flywheel is removed) (944 102 237 75)
• Needle bearings for clutch release lever (2) (999 201 089 00)
• Rear main oil seal (optional, recommended) (944 105 322 04)

Required Additional Procedures

Steps in these procedures are required to complete this process:

• Exhaust Manifold Removal and Installation
• Transaxle Removal and Installation
• Speed and Reference Sensor Replacement
• Allen Head and Cheesehead Bolt Removal

Step-by-Step Procedure

Step 1: Prepare the Vehicle

1. Place the car on jack stands to ensure a stable and safe working height.
2. Remove the belly pan using a 10mm (3/8 inch) socket to access the underside of the vehicle.
3. Disconnect the positive battery lead to prevent electrical hazards.

Step 2: Remove the Exhaust System

4. Remove the exhaust system from the exhaust headers back, including all hangers from the torque tube. Follow this link to ensure this step – Exhaust Manifold Removal and Installation – is followed accurately.

For Pre-85.5 models:

• The exhaust system may include a simpler manifold setup; ensure all bolts are removed carefully to avoid stripping.

For 85.5 Onwards models:

• The exhaust system may have updated hangers or brackets; verify all connections are detached.

Step 3: Access the Clutch Housing

5. Cover the timing mark window on top of the clutch housing with duct tape to prevent debris from entering.
6. Remove the speed and reference sensors from the top of the clutch housing. Follow this link to ensure this step – Speed and Reference Sensor Replacement – is followed accurately.
7. Disconnect the cable clamp next to the speed and reference sensors (alternator to starter wiring).
8. Disconnect the two ground wires on top of the clutch housing near the speed and reference sensors.
9. Remove the heat shield from the starter (if equipped) and disconnect the starter electrical leads.

For Pre-85.5 models:

• If equipped with a support bracket between the engine and clutch housing near the exhaust headers, remove it using a 13mm socket.

10. Remove the two starter retaining bolts using a 17mm socket and remove the starter.
11. Disconnect the cable clamp on the side of the clutch housing above the starter.

Step 4: Remove the Transaxle and Torque Tube

12. Remove the transaxle. Follow this link to ensure this step – Transaxle Removal and Installation – is followed accurately.
13. Remove the fuel filter to provide additional clearance.
14. Remove the transaxle carrier using a 15mm socket.
15. Disconnect the clutch slave cylinder from the clutch housing using a 13mm socket and secure it out of the way.
16. Support the engine under the oil pan with a floor jack and a wooden block to protect the pan.
17. Remove the four bolts attaching the torque tube to the clutch housing using a 17mm socket.
18. Remove the shift lever and shift lever base plate from the torque tube using a 10mm socket.
19. Slide the torque tube toward the rear of the car, rotating it 180° to clear the torsion bar tube.

Step 5: Remove the Clutch Assembly

20. Remove the clutch release lever retaining bolt from the clutch housing (above the starter opening) using a 13mm socket.
21. Thread a 150mm long, 8mm thread bolt into the release lever pivot shaft. Hold the bolt with locking pliers and tap with a hammer to remove the pivot shaft.
22. Remove the four clutch housing retaining bolts (two at the top, two at the bottom) using a 17mm socket.
23. Remove the clutch housing and release lever.
24. Using an 8mm cheesehead tool, loosen the pressure plate bolts evenly to prevent stripping. Follow this link to ensure this step – Allen Head and Cheesehead Bolt Removal – is followed accurately.

• Loosen all bolts partially before removing any to distribute tension evenly.

• To prevent the engine from turning, use one of these methods:

• Install two pressure plate bolts into the flywheel and hold a screwdriver between them for counter-torque.

• Have someone hold the crankshaft pulley bolt with a 15/16 inch socket.

• Clamp the flywheel edge with locking pliers.

25. Remove the pressure plate, release bearing, and clutch disc.
26. If resurfacing the flywheel, remove the flywheel bolts using a 12mm cheesehead tool and torque new bolts (944 102 237 75) to 90 Nm (65 ft-lbs).
27. Remove the pilot bearing from the crankshaft using a slide hammer bearing puller set.

• Alternatively, insert a bolt slightly smaller than the bearing opening, catch it behind the bearing, and tap with locking pliers and a hammer.

Step 6: Install New Clutch Components

28. If replacing the pressure plate, remove the toothed starter ring from the old pressure plate using a hammer and a wooden dowel, then install it on the new pressure plate (944 116 027 06), aligning bolt holes.
29. Install a new release bearing (944 116 080 00) on the pressure plate, reusing the snap ring if needed. Add spacers, insert into the pressure plate, and press down to install the snap ring.
30. Install a new pilot bearing (999 201 079 00) using a socket matching its outer diameter and a hammer. Apply a thin coat of molybdenum disulfide grease to the inner surface.
31. Install new needle bearings (999 201 089 00) in the clutch release lever and apply molybdenum disulfide grease to the bearings and rubbing surfaces.
32. If the flywheel was removed, install it and torque bolts to 90 Nm (65 ft-lbs).
33. Replace the guide sleeve in the clutch housing if needed, torquing bolts to 15 Nm (11 ft-lbs). Apply molybdenum disulfide grease to the inner surface.
34. Apply molybdenum disulfide grease to the splines of the new clutch disc (944 116 027 06) and the driveshaft.
35. Clean the flywheel and pressure plate friction surfaces with brake cleaner.
36. Ensure the flywheel pin points straight down.
37. Align the clutch disc to the flywheel using a clutch alignment tool, ensuring it’s fully inserted into the pilot bearing.
38. Install the pressure plate with new bolts (900 067 091 02), tightening gradually in a crisscross pattern. Torque to 25 Nm (18 ft-lbs).
39. Remove the clutch alignment tool.

Step 7: Reinstall the Clutch Housing and Transaxle

40. Apply molybdenum disulfide grease to the guide sleeve’s inner surface in the clutch housing.
41. Position the release lever in the clutch housing and install the housing onto the engine block, aligning with the pins. Torque bolts to 75 Nm (54 ft-lbs).
42. Slide the release lever pivot shaft into the clutch housing until fully seated.
43. Install the pivot shaft retaining screw and torque to 9.5 Nm (7 ft-lbs). Tighten the locking nut to 7.5 Nm (6 ft-lbs).
44. Push the torque tube forward and loosely bolt it to the clutch housing.
45. Install the transaxle carrier, torquing bolts to 46 Nm (33 ft-lbs).
46. Install the transaxle. Follow this link to ensure this step – Transaxle Removal and Installation – is followed accurately.
47. Install the clutch slave cylinder, torquing bolts to 21 Nm (15 ft-lbs).
48. Install the starter, torquing bolts to 45 Nm (32 ft-lbs), and attach the wiring harness. Reinstall the heat shield if equipped.
49. Attach the starter wiring harness to the clutch housing at two points with sleeve clamps.

For Pre-85.5 models:

• If equipped with a support bracket between the engine and clutch housing, install it and torque bolts to 42 Nm (30 ft-lbs).

50. Attach the ground straps to the top of the clutch housing, covering the access opening with tape to avoid dropping washers.
51. Install the exhaust system hangers onto the torque tube.
52. Install the exhaust system. Follow this link to ensure this step – Exhaust Manifold Removal and Installation – is followed accurately.
53. Install the speed and reference sensors. Follow this link to ensure this step – Speed and Reference Sensor Replacement – is followed accurately.
54. Attach the two ground wires to the top of the clutch housing near the speed and reference sensors.
55. Reinstall the belly pan using a 10mm (3/8 inch) socket.
56. Connect the battery positive lead.

Post Procedure Checklist

• Verify all bolts are torqued to the specified values (e.g., pressure plate bolts to 25 Nm (18 ft-lbs), clutch housing bolts to 75 Nm (54 ft-lbs)).
• Check the clutch pedal for smooth operation and proper engagement.
• Inspect for any leaks from the rear main oil seal (if replaced) or other components.
• Test drive the vehicle for 5 miles (8 km) to confirm smooth gear shifts and no clutch slippage.
• Ensure no unusual noises (e.g., grinding or rattling) come from the clutch or transaxle.

Sources

• Clark’s Garage
• Pelican Parts Technical Articles
• Porsche 944 Workshop Manual