Clutch Replacement

Overview

This guide walks you through replacing the clutch on a Porsche 944 S / S2 with its 16v engine. The clutch connects the engine to the transmission, allowing you to shift gears and control power delivery. Replacing it is a big job that takes time and patience, but it’s doable at home with basic mechanical skills. A worn clutch can slip or make shifting hard, so this procedure restores smooth driving.

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Tools Required

• Metric socket set (including 13mm and 15mm sockets)
• Metric wrench set (including 13mm and 15mm wrenches)
• 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
• Pliers (locking preferred)
• Hammer
• Molybdenum disulfide grease (MoS2)

Parts Required

• Clutch kit (includes clutch disc, pressure plate, release bearing) – 944 116 911 03
• Pilot bearing – 999 110 117 00
• Flywheel bolts (if resurfacing flywheel) – 944 102 211 00
• Pressure plate bolts (recommended new) – 944 116 081 00

Required Additional Procedures

Steps in these procedures are required to complete this process:

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

Step-by-Step Procedure

Step 1: Prepare the Car

1. Park the car on a flat surface and disconnect the positive battery lead.
2. Raise the car with a floor jack and secure it on jack stands.
3. Remove the belly pan under the car using a 13mm wrench.

Step 2: Remove the Exhaust System

4. Follow this link to ensure this step – Exhaust Manifold Removal and Installation – of the process is followed accurately to remove the exhaust system from the headers back.
5. Take off all exhaust hangers from the torque tube using a 13mm wrench.

Step 3: Access the Clutch Housing

6. Tape over the timing mark window on top of the clutch housing with duct tape to keep debris out.
7. Follow this link to ensure this step – Speed and Reference Sensor Replacement – of the process is followed accurately to remove the speed and reference sensors from the clutch housing.
8. Disconnect the cable clamp next to the sensors and the two ground wires on top of the clutch housing using a 13mm wrench.
9. Remove the starter heat shield (if present), disconnect the starter wires, and remove the two starter bolts with a 13mm wrench. Take the starter out.

Step 4: Remove the Transaxle and Torque Tube

10. Follow this link to ensure this step – Transaxle Removal – of the process is followed accurately to remove the transaxle.
11. Support the engine under the oil pan with a jack and a wood block to protect the pan.
12. Remove the four bolts attaching the torque tube to the clutch housing with a 13mm wrench.
13. Take off the shift lever and its base plate from the torque tube.
14. Slide the torque tube toward the rear, rotating it 180° to clear the torsion bar tube.

Step 5: Remove the Clutch Components

15. Unscrew the clutch release lever retaining bolt above the starter opening with a 13mm wrench.
16. Thread a 150mm long, 8mm bolt into the release lever pivot shaft. Tap it out with pliers and a hammer.
17. Remove the four clutch housing bolts (two at the top, two at the bottom) with a 15mm wrench and take off the housing and release lever.
18. Use an 8mm Cheesehead tool to loosen the pressure plate bolts evenly. Follow this link to ensure this step – Allen Head and Cheesehead Bolt Removal – of the process is followed accurately. Hold the flywheel with a screwdriver between two bolts or clamp it with locking pliers to stop it from turning.
19. Remove the pressure plate, release bearing, and clutch disc.

Step 6: Remove the Pilot Bearing

20. Use a slide hammer bearing puller to remove the pilot bearing from the crankshaft end. Tap it out gently if needed.

Step 7: Install New Clutch Components

21. Tap a new pilot bearing (999 110 117 00) into the crankshaft with a socket and hammer, applying a thin layer of MoS2 grease inside.
22. Grease the new release bearing and clutch release lever bearings with MoS2. Attach the release bearing to the new pressure plate (944 116 911 03).
23. Clean the flywheel and pressure plate surfaces with brake cleaner.
24. Align the new clutch disc (944 116 911 03) to the flywheel using a clutch alignment tool, ensuring it fits into the pilot bearing.
25. Install the pressure plate with new bolts (944 116 081 00), tightening them gradually in a crisscross pattern to 25 Nm (18 ft-lbs).

Step 8: Reassemble the Clutch Housing

26. Coat the clutch housing guide sleeve with MoS2 grease and install the housing onto the engine block. Tighten the four bolts to 75 Nm (54 ft-lbs).
27. Slide the release lever pivot shaft into place and secure it with the retaining screw, torquing to 9.5 Nm (7 ft-lbs).
28. Push the torque tube forward and loosely bolt it to the clutch housing.

Step 9: Final Reassembly

29. Follow this link to ensure this step – Transaxle Installation – of the process is followed accurately to install the transaxle.
30. Install the clutch slave cylinder and torque its bolts to 21 Nm (15 ft-lbs).
31. Reinstall the starter, torque its bolts to 45 Nm (32 ft-lbs), and reconnect the wiring.
32. Attach the ground wires and sensors, then reinstall the exhaust system using the Exhaust Manifold Removal and Installation procedure.
33. Put the belly pan back on and reconnect the battery.

Post Procedure Checklist

• Press the clutch pedal to check for smooth operation—no grinding or stiffness.
• Start the car and test shifting through gears while stationary.
• Drive 5 miles (8 km) and listen for unusual noises or slipping.
• Check under the car for leaks or loose bolts.

Sources

• Clark’s Garage Clutch Replacement
• Youtube
• Pelican Parts