DISCLAIMER2020 Porsche Boxster S (986) F6-3.2L Technical Service Bulletin # 32/03 Date: 031024
M/T - Clutch Pedal Sticking
Boxster
2/03 3001
Binder - 3, Manual Transmission
Date: 10-24-03
Vehicle Type:
Boxster/Boxster S
Model Year:
As of '97 (V)
Concerns:
Hydraulic clutch actuation and installing snap ring in the groove of the plug-in couplings of the clutch pipeline.
2020 Porsche Boxster S (986) F6-3.2L Page 28
Information:
With hydraulic clutch actuation, the clutch pedal may not return to its initial position or may become stuck as a result of the axial play in the plug-in
couplings of the clutch pipeline (Figure 1, Items 1, 2 and 3). The axial motion in the plug-in couplings and the associated rolling of the sealing ring
can admit air into the hydraulic system.
In the event of a complaint, a snap ring, Part Number, 999 230 685 40, must be fitted in the groove of the plug-in couplings in the area of the
plenum chamber, underbody and transmission (Figure 1, Items 1, 2 and 3). The clutch system must then be bled. The procedure for filling the snap
rings is described in this bulletin.
Parts Information:
Required Tools:
Work Procedure:
Filling snap ring in the groove of the plug-in couplings.
1. Filling snap ring in the groove of the plug-in coupling in the plenum chamber (Figure 1, Item 1). The plug-in coupling (Figure 1, Item 1) is
located in the plenum chamber on the left side at the front of the vehicle.
1.1 Open the luggage compartment lid and remove the plenum chamber cover on the leftside of the vehicle.
1.2 Check whether the plug-in coupling is correctly engaged (see step 4).
1.3 Position the snap ring in the groove of the plug-in coupling and apply slight pressure to press it over the plug shank until it engages (Figure 1,
Item A).
1.4 Fit plenum chamber cover.
2. Fitting snap ring in the groove of the plug-in coupling on the underbody (Figure 1 Item 2). The plug-in coupling (Figure 1, Item 2) is located
near the center of the vehicle on the underbody at left side of the vehicle.
2.1 Remove the left underbody panel near the center of the vehicle.
2.2 Check whether the plug-in coupling is correctly engaged (see step 4)
2.3 Position the snap ring in the groove of the plug-in coupling and apply slight pressure to press it over the plug shank until it engages (Figure 1,
Item A).
2.4 Fit the underbody panel
3. Fitting snap ring in the groove of the plug-in coupling in the area of the transmission (Figure 1, Item 3). The plug-in coupling (Figure 1, Item
3) is located on the body near the transmission on the left vehicle side.
3.1 Check whether the plug-in coupling is correctly engaged (see step 4)
2020 Porsche Boxster S (986) F6-3.2L Page 29
3.2 Position the snap ring in the groove of the plug-in coupling and apply slight pressure to press it over the plug shank until it engages (Figure 1,
Item A).
4. Checking whether plug-in coupling has engaged properly.
4.1 Insert special tool 9623 into the groove of the plug-in coupling (Figure 2) and check the engagement by applying slight pressure on the
special tool. The plug must not slide out. If the special tool cannot be inserted into the groove, widen the grove by pulling lightly on the plug
(pull on the plug without using excessive force).
Note:
The plug-in coupling is designed so that the plug can be shifted in the plug-in coupling by approx. 1 mm in axial direction by slightly
pulling or pressing.
5. Concluding work. At the end of the work, the clutch system must be bled. The procedure is described in the Boxster Technical Manual,
Group 3, Repairs: 30-5 - Bleeding the clutch operation system.
Literature:
Boxster Technical Manual, Group 3:
> Repairs: 30-5 - Bleeding the clutch operation system