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Removing and installing clutch slave cylinder: Installation

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2005 Porsche 911, 2004 Porsche 911, 2003 Porsche 911, 2002 Porsche 911, and 2001 Porsche 911. However, it is still accessible from the selected car via links, so may be relevant.
  1. Grease end of the push rod of the clutch slave cylinder - in the area located in the ball socket of the release lever when installed - with a thin coat of Olista Longtime 3 EP (available as a spare part).
  2. Fit the clutch slave cylinder and tighten the fastening screws (23 Nm (17 ft.lb.)).
    NOTE: When inserting clutch slave cylinder, it is necessary to overcome the spring force acting on the push rod whilst fitting a fastening screw. Refer to the assembly instructions in the following text.

    Assembly instructions for inserting the clutch slave cylinder 

    • Move clutch slave cylinder to installation position and then fix/centre it at the lower fastening point using a drift punch (A) measuring 5 x 120 x 10 mm.
    • Align clutch slave cylinder - with the drift punch (A) in place - so that the upper fastening screw No. 3 can be fitted.
    • After fitting the upper fastening screw No. 3, remove the drift punch (A) and screw in the lower fastening screw.
      • Fig 1: Aligning Clutch Slave Cylinder With Drift Punch
      G03105191Courtesy of PORSCHE OF NORTH AMERICA, INC.
    • Tighten upper and lower fastening screws (23 Nm (17 ft.lb.)).
  3. Fit clutch line on clutch slave cylinder (do not tighten it yet). Fit holder with clip on the transmission side cover (tightening torque of the two screws: 25 Nm (19 ft.lb.)). Clip clutch line into the holder and tighten the line.
  4. Bleed hydraulic system of the clutch. See BLEEDING THE CLUTCH SYSTEM .
    NOTE: The clutch hydraulics must always be filled or bled using a pressure filling and bleeding device. Furthermore, the bleeder valve must be opened sufficiently and the gauge pressure must be approx. 1.5 bar. Before the system is filled or bled, the clutch pedal must be in the "Pedal fully depressed" position.
    WARNING: As there is no system pressure, servo kinematic effects will cause the clutch pedal to move forward abruptly. In order to avoid damage, the pedal must be guided manually. Bleed the system until no more bubbles appear at the bleeder valve (use a collecting bottle with transparent hose). If the system was open previously, the minimum filling or bleeding time must be 30 seconds.
  5. Check operation of the clutch. Repeat the bleeding process if the clutch does not operate (disengage) correctly.
  6. Install rear axle cross member. Tightening torque of the two screws 65 Nm (48 ft.lb.).
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