Porsche Boxster 986 Clutch Replacement (Project 44)

Project 44: from the 101 Projects for your Porsche Boxster book
This video shows you how to remove and replace the clutch in a 1997 base Porsche Boxster 986. Complete step-by-step DIY guide!
MAKE SURE TO GET A CLUTCH ALIGNMENT TOOL! I can't seem to find a separate link for one.
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Clutch + Flywheel Kit: bit.ly/3QCbN5S
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Transmission Removal Video: • Porsche Boxster 986 Tr...
RMS Replacement VIdeo: • Porsche Boxster 986 RM...
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BMW: bit.ly/3qqiBs3
101 Projects for your Porsche Boxster book:
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986 Service Manual:
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Disclaimers
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I am a Do It Yourself, also known as DIY, mechanic. I am NOT a professional mechanic. I do not have any formal training in the automotive field.
Help Me DIY assumes no liability for anything you choose to do to your car, before, or after watching one of my videos or utilizing the content from this web site.
All DIY repairs or modifications you perform to your car are made at your own risk. Sometimes, even if you've done everything the right way, you can destroy or damage one or more things on your car. You must understand this, but by leveraging knowledge and patience, the probability of encountering one or more problems can be reduced.
Also, if for some unfortunate reason, I do give incorrect instructions and something breaks because you followed my instructions, I will NOT reimburse or pay in any way for whatever cost that may be incurred due to following my wrong instructions.
Lastly, please don't do anything to your car unless you yourself feel comfortable and confident in doing so.

[@tomsneed5021]

Just successfully finished this project an hour ago on my 2004 986 with quick jacks and your video series. Your videos were a godsend, many thanks! 🙌🏻

[@HelpMeDIY]

+Tom Sneed that’s great! 🍻

[@AaronS11979]

To help with that flywheel, you could take the old bolts (because you're replacing them) and cut off the heads for two or three with an angle grinder. Then hand thread them in a few turns to use as dowels to hold the flywheel and align it. Like you do for the wheel studs to hold the wheel in place. Once you get a real bolt in, hand remove them and then throw them away.

[@HelpMeDIY]

+@AaronS11979 great idea! 🍻

[@RockyTopAviator]

Great video, gives me hope for being able to replace my own clutch one day. Thanks!

[@HelpMeDIY]

+Jacob L. Thanks! You can do it. 🍻

[@bobrose513]

Hi Aran. Have they changed get the rear main seal. And checked the IMS. No going g to all that trouble and not doing it. Or has it been done earlier..regards Bob Rose cosworth Northampton uk

[@HelpMeDIY]

+Bob Rose we did the RMS. It’s in a separate video.

[@minermarcus]

You forgot to show us you testing the dual mass flywheel by twisting it to see it lash back. All that work to get in there I might have replaced more. Definitely the RMS.

[@HelpMeDIY]

+minermarcus we did the RMS. I mentioned that. That video is coming soon.

[@alexstowers3706]

Thank you!

[@HelpMeDIY]

+Alex Stowers you’re welcome! 🍻

[@FreePalestine1173]

You’re supposed to lock the flywheel to do this job right

[@HelpMeDIY]

+Alex Bailey lock it? You remove it 🤷‍♂️

[@silver911100]

The base and s have different input shaft sizes 15/16 vs 1" ask me how I know 🤬

[@HelpMeDIY]

+elliot p. ness doh! 🤦‍♂️

[@ronzautokars5034]

Sir, which tranmssion? Manual or tiptronic? I am thinking to replace my clutch as well with tiptronic transmission with torque convertwr, does mine have the throwout bearing as well?

[@HelpMeDIY]

+Ronz Autokars that’s a manual transmission. I just posted a video today on the tiptronic

[@hardtmuth1]

Are you sure that you properly tighten this bolts to 120 degrees after 25 Nm? When the flywheel moved does the wrench not think that you tighten the bolts by those degrees? As I've seen somewhere else doing the cluch they locked flywheel with a steel plate and 2 bolts, one for flywheel and second for engine block.

[@HelpMeDIY]

+Leszek Kaczmarek yup. Well… he messed it up a little at some points, but when the flywheel moves the torque wrench just rotates with it and does not actually turn the pivot that registers degrees

[@hardtmuth1]

@@HelpMeDIY everything is clear. Thanks;)

[@JimBob_1975]

Can you tell me how you support the engine once the gearbox has been removed? Thanks

[@HelpMeDIY]

+James Dickenson I have a tall jack stand under it essentially

[@JimBob_1975]

@@HelpMeDIY Thanks

[@Marscommander1]

This whole job didn't really feel up to your usual quality and methodical work. I understand it was another's vehicle, but some of the work represented here were pretty hack-y and questionable. Just an observation, hope it works out for the guy. Cheers.

[@HelpMeDIY]

+Marscommander1 well it was a learning experience for everyone. I always try to include the “what to do” as well as the “what not to do” side of the job, so hopefully it will help people see everything the job entails. 🍻

[@bobrose513]

Not sure why your standing on a chair. When you have a two post lift. Just lower the engine brace that you have holding up the engine.

[@HelpMeDIY]

+Bob Rose haha it was just easier than lowering them at the same time 🤷‍♂️. Lazy often wins.

[@19lol19]

I'm surprised nobody scraped their fingers up

[@HelpMeDIY]

+Peanut Man 30 fingers. 0 scrapes 😆

[@19lol19]

@@HelpMeDIY hell all my knuckles would have scrape marks...lol

[@minermarcus]

@Peanut Man my knuckles would have been in mechanics gloves.

[@ralfsautomotive]

You do realize that the Flywheel should have been surface ground?!! Installing that clutch like that was as wrong as wrong could be.

[@HelpMeDIY]

+Ralf's Automotive Diagnostics & Repair you could do that, but your statement is just false. Owner reported a much better clutch feel afterwards. Mission accomplished! There were infinitely more “wrong” things that could have been done so that’s nonsense.

[@ralfsautomotive]

@@HelpMeDIY I don't even know what to say to that. You obviously have no clue what you are doing based on that statement. May I suggest a quick google search why it is necessary to resurface Rotors and Flywheels! Maybe you get an Idea why that is.

[@HelpMeDIY]

@@ralfsautomotive same

[@networkbits8958]

gringy mechanic...wanting to re use the stretched out bolts and glazed flywheel