Notes on removal and installation: 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.

Inspect all bearing bushings X for clutch pedal lever and replace them if necessary. Lubricate sliding surfaces of the bearing bushings X and the pedal bearing axle with Optimol, Optitemp LG 2, Part No. 000.043.203.37. Refer to Fig 1.
Assemble boost spring, bracket and clutch pedal lever. Description under step 2.1 or 2.2.
1. 2.1 Carrera (996) Mod. '98 / some Mod. '99
2. 2.2 Carrera (996) from 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.
A modified (optimised) clutch pedal must also be sometimes be using 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).

Information can be found in CLUTCH BOOST SPRINGS: ALLOCATION AND GREASE SPECIFICATION .
1. 2.1 Carrera (996) 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 1: Identifying Boost Spring Greasing Areas
  Courtesy of PORSCHE OF NORTH AMERICA, INC.
2. 2.2 Carrera (996) from 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).

Fig 2: Engaging Hexagon Bolt Of Boost Spring In Hexagon On Clutch Pedal
Courtesy of PORSCHE OF NORTH AMERICA, INC.

WARNING: 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).

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 from current Mod. '99) must be used only in this combination and installed only in the 911 Carrera (996).
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 Nm (7.5 ft.lb.) (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.

Tightening torque: 7.5 Nm (5.5 ft.lb.).

Sequence: 5a / 5b / 5c . Refer to Fig 3.

Fig 3: Tightening Hexagon Nuts In Prescribed Sequence
Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: The push rod of the clutch slave cylinder should not be lubricated in general (for all versions).
Fit new retainer on the pedal bearing axle and subsequently secure the retainer by wedging it with a mandrel.
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.
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 4: Aligning Interlock Switch
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Install relay carrier, diagnostic socket and air duct.
Perform a function test on clutch and brake operation.