Porsche 914 - How to Replace the Clutch and Flywheel

Introduction

In this tutorial, you will learn how to replace the clutch and flywheel on a 1974 Porsche 914. This guide is designed for DIY enthusiasts and provides step-by-step instructions to help you complete the task safely and effectively.

Step 1: Prepare for the Clutch Replacement

• Assess the Situation: Confirm that the clutch needs replacement by checking for signs such as slipping during acceleration.
• Gather Tools and Parts: You will need:
  • New clutch disc and pressure plate
  • Flywheel bolts
  • Rear main oil seal
  • Felt washer and O-ring
  • Clutch alignment tool
  • Flywheel lock tool
  • Socket set (17mm)
  • Torque wrench
• Safety First: Ensure you are working in a safe environment with appropriate safety gear.

Step 2: Remove the Engine and Transmission

• Separate the Transmission:
  • Locate the four 17mm bolts connecting the transmission to the engine.
  • Remove the bolts, including the one that doubles as the starter anchor.
  • Pull out the reverse switch connector carefully to avoid damage.
• Engine Handling: Use a crane or engine hoist to lift the engine and place it on a stand for easier access.

Step 3: Inspect and Remove Old Components

• Check the Existing Clutch:
  • Look for signs of wear such as grooves and burning marks on the pressure plate and flywheel.
  • Vacuum any debris carefully to avoid inhaling harmful materials.
• Remove the Pressure Plate:
  • Use the flywheel lock tool for leverage on the bolts.
  • Remove the pressure plate bolts and pry off the plate gently.

Step 4: Replace the Flywheel

• Remove Flywheel Bolts:
  • Lock the flywheel in place again before loosening the 17mm bolts.
  • Work around the flywheel carefully to avoid injury.
• Replace Rear Main Seal:
  • Use a seal puller to remove the old seal without damaging the engine case.
  • Install a new rear main seal using a wood shim for even pressure.

Step 5: Check and Adjust Crank End Play

• Measure End Play:
  • Use a dial gauge to measure the crankshaft movement.
  • Ensure the end play is within the 3 to 5 thousandths of an inch range.
• Adjust Shims:
  • Reuse existing shims or replace with new ones as necessary to achieve correct measurements.

Step 6: Install New Components

• Install New Flywheel:
  • Make sure to align the indexing pin and apply grease to the needle bearings.
  • Torque flywheel bolts to 79.5 foot-pounds using a crisscross pattern.
• Install Clutch Disc and Pressure Plate:
  • Use the alignment tool to position the clutch disc.
  • Torque the pressure plate bolts to 14.5 foot-pounds.

Step 7: Reassemble and Test

• Reattach the Engine:
  • Carefully lift the engine back into the car and reattach the transmission.
• Final Checks:
  • Double-check all connections and ensure no tools are left inside the engine bay.

Conclusion

Replacing the clutch and flywheel on your Porsche 914 can be a rewarding project if approached methodically. With the correct tools and careful attention to detail, you can enhance your vehicle's performance and prolong its lifespan. Always ensure safety is your priority, and consider consulting a professional mechanic if you encounter uncertainties. Happy driving!