Troubleshooting – Clutch

Overview

This guide helps you identify and fix common clutch issues on your Porsche 944 S / S2 with the 16v engine. A properly working clutch is essential for smooth gear changes and driving performance. We’ll cover symptoms like a soft pedal, slipping clutch, or unusual noises, offering step-by-step checks and solutions.

Pink and blue text represents links to additional resources, tools, parts, and partner websites.

Tools Required

• 10mm (3/8 inch) wrench
• 13mm wrench
• Screwdriver (flathead)
• Bleed kit or turkey baster (for bleeding clutch)
• Flashlight (for inspections)

Parts Required

• Clutch master cylinder, 944 116 027 03 (if rebuilding or replacing)
• Clutch slave cylinder, 944 116 237 03 (if rebuilding or replacing)
• Clutch disc, 944 116 027 06 (spring-centered, for replacement)
• Pressure plate, 944 116 027 05 (if replacing)
• Release bearing, 944 116 080 04 (if replacing)
• Pilot bearing, 944 116 080 03 (if replacing)
• Brake fluid (DOT 4)

Required Additional Procedures

Steps in these procedures are required to complete this process:

• Clutch Replacement
• Clutch Bleeding
• Clutch Disc Wear Check
• Troubleshooting – Manual Transmission

Step-by-Step Procedure

Step 1: Clutch Pedal Travels to Floor with Little or No Resistance

1. Check the clutch master cylinder and slave cylinder for leaks. Look around the firewall (master cylinder) and under the car near the transmission (slave cylinder) for brake fluid dripping. If you see leaks, rebuild or replace the faulty cylinder using 944 116 027 03 for the master or 944 116 237 03 for the slave.
2. Have someone press the clutch pedal while you watch the brake fluid reservoir. If the fluid level rises as the pedal goes down, the master cylinder is bad. Replace it with 944 116 027 03.
3. Inspect the hose from the brake fluid reservoir to the master cylinder and the line to the slave cylinder for leaks. Tighten fittings with a 13mm wrench or replace the hose if damaged.
4. If the brake fluid reservoir is low, fill it with DOT 4 fluid. If the pedal feels spongy afterward, bleed the clutch. Follow this link to ensure this step – Clutch Bleeding – of the process is followed accurately.
5. Use a flashlight to look into the clutch housing’s round opening. Push the release lever with a screwdriver. If it moves too easily, it might be broken. Replace the clutch assembly if needed. Follow this link to ensure this step – Clutch Replacement – of the process is followed accurately.

Step 2: Clutch Pedal Feels Soft When Depressed

6. Check the brake fluid reservoir level. If it’s below the hose to the master cylinder, fill it with DOT 4 fluid. Bleed the clutch if the pedal still feels soft. Follow this link to ensure this step – Clutch Bleeding – of the process is followed accurately.

Step 3: Unable to Engage Transmission into Gear

7. Test the clutch: With the engine running, try shifting into gear. If it won’t shift but works with the engine off, the clutch disc or pressure plate might be bad.
8. Check the clutch disc condition. Follow this link to ensure this step – Clutch Disc Wear Check – of the process is followed accurately. If worn, replace it with 944 116 027 06.
9. If the pressure plate is suspected, replace it with 944 116 027 05. Follow this link to ensure this step – Clutch Replacement – of the process is followed accurately.
10. If the clutch seems fine, the issue might be in the transmission or shift linkage. Follow this link to ensure this step – Troubleshooting – Manual Transmission – of the process is followed accurately.

Step 4: Clutch Slips

11. Look for oil or coolant leaks at the back of the engine with a flashlight. Check the clutch housing bottom for dripping. If contaminated, replace the clutch disc with 944 116 027 06. Follow this link to ensure this step – Clutch Replacement – of the process is followed accurately.
12. Check clutch disc wear. Follow this link to ensure this step – Clutch Disc Wear Check – of the process is followed accurately. Replace if worn with 944 116 027 06.
13. If no leaks or wear are found, the pressure plate or flywheel might be warped. Replace the clutch assembly. Follow this link to ensure this step – Clutch Replacement – of the process is followed accurately.
14. If the clutch was heavily used (e.g., at a track), let it cool for an hour. Test again to see if slipping stops.

Step 5: Clutch Grabs or Shudders as It Engages

15. Inspect for oil or coolant leaks at the engine’s rear. If the clutch disc is contaminated, replace it with 944 116 027 06. Follow this link to ensure this step – Clutch Replacement – of the process is followed accurately.
16. Note your driving style. Quick clutch engagement (jabbing) can cause shudder over time. Try engaging it slowly to see if it improves.
17. If shudder persists, the pressure plate or flywheel might be warped, or the clutch disc splines worn. Replace the clutch assembly. Follow this link to ensure this step – Clutch Replacement – of the process is followed accurately.

Step 6: Noise or Vibration from Clutch Area

18. Listen for excessive noise. A bad release bearing (944 116 080 04) or pilot bearing (944 116 080 03) could be the cause. Replace them. Follow this link to ensure this step – Clutch Replacement – of the process is followed accurately.
19. If the pressure plate has a broken spring, replace it with 944 116 027 05. Follow this link to ensure this step – Clutch Replacement – of the process is followed accurately.
20. For the S2’s spring-centered clutch disc, check for a broken spring. Replace with 944 116 027 06 if damaged. Follow this link to ensure this step – Clutch Replacement – of the process is followed accurately.

Post Procedure Checklist

• Press the clutch pedal to ensure it feels firm and returns fully.
• Check for leaks around the master cylinder, slave cylinder, and clutch housing.
• Test shifting into all gears with the engine running.
• Listen for unusual noises or vibrations while engaging the clutch.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manual, Volume 1
• Youtube