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Boxster S Clutch problem year 2000


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Hi,

 

I'm having clutch problem with my Boxster S, 6-speed (year 2000) with only 90 000 km (~56 000 miles) on the clock.

 

All started one day when driving normally on a highway and taking exit. I pressed clutch pedal and it felt spongy and like it was going to stay down. It had pretty much zero feel. Before this no problems what so ever and now all of sudden this started.

I called a local guy who have been servicing the car if I had any problems and we discussed it might be either main or clave cylinder so I ordered new ones from Ebay and continued driving. There wasn't any leaks from these two. I had to wait new cylinders to arrive and continue driving. Clutch stayed the same, still zero feel but it didn't go any worse and it also returned every time when pressed down although it always felt it's gonna stay down.

 

Both cylinders arrived and went to change those. Got new parts in place and bled the system. Slave cylinder was pretty hard to install to it's place, should it be? Like when the metal pin was in the hole you had to seriesly push the whole thing with fingers to get slave cylinder bolt to it's place (otherwise it was like 4 cm off from the correct place)

Cylinder replacement made clutch feel a bit better but still it didn't returned what it was before all this started.

 

Went for a test drive and only now I realized to try hard acceleration. When changing 1st -> 2nd and pressing throttle to the floor noticed a huge clutch slip. Clutch slippage also occured what ever gear when flooring the throttle. We lifted the car back up and took slave cylinder out. We took the metal center pin from the old clutch cylinder and used that since it was shorter than the one which the new slave cylinder had. We thought the metal pin might be too long and therefore the clutch is not fully released although clutch pedal isn't pressed.

So went with the shorter one now. Still slave cylinder was a bit tight to get in the place but lot easier than with the longer metal pin.

 

This also corrected the slippage a lot but still especially 1st -> 2nd gear hard accleration I get clutch slipping. Not so much on the higher gears but varies. Sometimes it slips and sometimes it doesn't on higher gears like in 4th gear.

 

Is there anything I can do do besides taking transmission out and replacing the clutch, and also flywheel? IMS will have to be done at the same time if we have to go there. Could the problem still be in the slave cylinder and is there any tips I could confirm the situation it's the worn clutch causing all the problems? It feels a bit strange cause the problem started all at once. One clutch pedal push down and it went spongy and lost it feel. Shouldn't clutch disc problems develop slower?

 

 

Thanks in advance!

Edited by Mikluuutus
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  • Moderators

 

A cracked diaphragm spring is in such case mostly the culprit.

 

Where is this spring located exactly? Do I need whole clutch kit to get it fixed?

 

 

It is part of the pressure plate assembly, and yes, you will need to replace the clutch to fix it.

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