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Notes on removal and installation: Installation

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  1. Inspect all bearing bushings X for clutch pedal lever and brake pedal and replace them if necessary. Refer to Fig 1 . Lubricate sliding surfaces of the bearing bushings X and the pedal bearing axle with Optimol, Optitemp LG 2, part No. 000.043.203.37.
    Fig 1: Sectional View Of Clutch Pedal Lever Area Components
    G03105879Courtesy of PORSCHE OF NORTH AMERICA, INC.
  2. Fit brake pedal and stop light switch. Tightening sequence of the pedal bearing axle (refer to Figure ): No. 4 = Pedal bearing axle (8...10 N.m (6.0...7.5 ftlb.)) No. 3 = Hexagon nut (10 N.m (7.5 ftlb.)) No. 2 = Lock nut for steering outer tube (20 N.m (15 ftlb.))
    NOTE:
  3. Assemble boost spring, bracket and clutch pedal lever. Description under step 3.1 or  3.2.
    1. 3.1 Carrera Mod. '98 / some Mod. '99
    2. 3.2 Carrera as of current Mod. '99.
    NOTE: In the 911 Carrera (996), different boost springs may be fitted. Observe proper allocation when replacing the boost spring and/or the bracket.

    In some cases, a modified (optimised) clutch pedal must also be used when replacing the boost spring.

    Greasing of the boost spring bearing points is partly necessary and partly not permitted (depending upon the type of boost spring used).

    Please refer to CLUTCH BOOST SPRINGS: ALLOCATION AND GREASE SPECIFICATION .

    allocation and grease specification.

    3.1 Carrera Mod. '98 / some Mod. '99 

    Identification/differentiation:

    Push rod of boost spring open on one side, boost spring parts not coated.

    Grease pin for boost spring (arrow) with mating bearing on the boost spring push rod, the boost spring bearing (arrows) and the bearing pins on the boost spring with Optimol, Optitemp LG 2, Part No. 000.043.203.37.

    First remove old grease with solvent naphtha.

    Greasing necessary (arrows)

    Fig 2: Locating Greasing Areas For Boost Spring
    G03105880Courtesy of PORSCHE OF NORTH AMERICA, INC.

    3.2 Carrera as of current Mod. '99 

    Identification/differentiation:

    Push rod closed / boost spring parts coated. The date of introduction for this boost spring is contained in the Parts Catalogue.

    Engage the hexagon bolt of the boost spring in the hexagon on the clutch pedal (arrow)

    Important: Do not grease, as the sliding surfaces of this type of boost spring are coated.

    This non-greasing instruction applies to all sliding surfaces (pin of boost spring, boost spring bearing in bracket, bearing pin on boost spring and boost spring in the shell).

    Fig 3: Identifying Hexagon Bolt On Clutch Pedal
    G03105881Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Do not grease (not permitted).

    NOTE: Gold-coloured bracket (996.423.571.00) and boost spring with purple marking (996.423.081.09 Mod. '98 / some Mod. '99 or 996.423.081.11 as of current Mod. '99) must be used only in this combination and installed only in the 911 Carrera (996).
  4. Installation and adjustment specification for boost spring bracket. Install preassembled boost spring bracket with clutch pedal lever.

    To do this: 

    Step 1: Tighten the three fastening nuts (arrows) only slightly (the bracket must still be movable).

    Step 2: Tighten the clutch master cylinder to 10 N.m (7.5 ftlb.) (if the clutch master cylinder was detached).

    Step 3: Press the clutch pedal against the direction of travel until the pull stop in the clutch master cylinder is reached.

    Step 4: Remove cotter pin (retaining pin) on the spring cup so that the clutch pedal is pressed against the rubber stop in the boost spring bracket.

    Step 5: The bracket is screwed down with the clutch pedal pressed back (to make full use of the slots).

    Tighten hexagon nuts (arrows) in the prescribed sequence. Refer to Fig 4 . Tightening torque: 7.5 N.m (5.5 ftlb.).

    Sequence: 5a / 5b / 5c

    Fig 4: Identifying Boost Spring Bracket Components
    G03105882Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE: The push rod of the clutch save cylinder should not be lubricated in general (for all versions).
  5. Fit new retainer on the pedal bearing axle and subsequently secure the retainer by wedging it with a mandrel.
  6. Install clutch pedal switch. First pull operating plunger out of the switch as far as it will go. By means of its self-adjustment function, the switch then compensates for tolerances in the pedals.
  7. Check the interlock switch adjustment on vehicles with interlock.

    Adjustment specification for interlock switch: 

    The switch must be aligned so that, with the clutch pedal depressed, it is operated approx. 1 to max. 2 mm before the limit stop of the clutch slave cylinder is reached.

    Fig 5: Checking Interlock Switch Adjustment
    G03106267Courtesy of PORSCHE OF NORTH AMERICA, INC.
  8. Install relay carrier, diagnostic socket and air duct.
  9. Perform a function test on clutch and brake operation.
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