M/T - Clutch Pedal Doesn't Return To Original Position

3

911 (997)

5/05

ENU

3001

Clutch Pedal Does Not Fully Reach its Original Position

Vehicle Type:
911 Carrera (997)/911 Carrera S (997)

Model Year:
As of 2005

Equipment:
Manual transmission (G97/01)

Concerns:
Clutch hydraulic system

Information:
After pressing the clutch, the clutch pedal is slow to come backup and does not fully reach its original position.

This is caused by air in the hydraulic system. In the event of a complaint, bleed the hydraulic system according to the revised instructions in the Workshop Manual, --> see Enclosure and Preliminary information --> Workshop Manual '300107 Bleeding the clutch system'.

If, contrary to expectations, the problem occurs again after you have carried out the required remedial action, the following procedure applies:

1 Visually check the clutch pipeline close to the plug connections for leaks. It you find a leak, replace the affected threaded joint. The procedure for replacing threaded joints is described in --> Workshop Manual (986) '302331 Converting clutch line on master cylinder' (--> Step 8).

2 Visually check the clutch master cylinder for leaks. If you find a leak, replace the master cylinder, --> Workshop Manual '300519 Removing and installing the clutch pedal'.

3 Replace the clutch slave cylinder.

4 Bleed the hydraulic system according to the revised instructions in the Workshop Manual, --> see Enclosure and Preliminary information --> Workshop Manual '300107 Bleeding the clutch system'.





Parts Info:

References:

--> Workshop Manual '300519 Removing and installing the clutch pedal'.
--> Workshop Manual '300107 Bleeding the clutch system'.

--> Workshop Manual (986) '302331 Converting clutch line on master cylinder' --> (Step 8).

Enclosure:
--> Workshop Manual '300107 Bleeding the clutch system'.

Bleeding the clutch system

Filling/bleeding

Information
In general, a minimum filling time of 90 seconds must be observed.

Use only new Super DOT 4 class brake fluid. This brake fluid is available under the following part numbers:

^ Container quantity 1 liter = 000.043.203.66

^ Container quantity 30 liters = 000.043.203.67





1 Remove the cover over the brake fluid reservoir. Fill reservoir to its top edge with new brake fluid. Connect the bleeding device to the brake fluid reservoir. --> see figure

2 Switch on the bleeding device and set an overpressure of approx. 1.3 bar.





3 Open the bleeder valve --> see figure -arrow- on the clutch slave cylinder.

4 Move pedal extremely slowly to the "Pedal fully depressed" position. When doing so, guide the pedal by hand so that it does not move forward abruptly.

5 Allow the brake fluid to rinse through for 30 seconds.

6 Afterwards, activate complete pedal travel manually very slowly for a further 60 seconds. After about 10 to 15 pedal strokes, leave the pedal in its normal position. Once this filling period has elapsed, check that no more bubbles appear at the bleeder valve (use a collecting bottle with transparent hose). Then close the bleeder valve (tightening torque = 7 + 6 Nm (5 + 4.5 ftlb.).

7 Switch off and disconnect the bleeding device. Check the brake fluid level. It should not be above the MAX. mark.

8 Activate the clutch pedal slowly, five times.

9 Fit the cover over the brake fluid reservoir.





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