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1984 5sp Won't Enter Gears
- Atour
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14 Oct 2024 07:45 #22754
by Atour
1984 5sp Won't Enter Gears was created by Atour
Hi everyone,
I have a 1984 928 5sp that I've been slowly working on catching up past due maintenance. All while regularly driving the car. 4 months ago, while driving the car, the clutch pedal went mushy. Since I was far from home and around a certified classics Porsche dealership, I figured it wouldn't hurt to check the car in with Porsche and have them look over the car.
I was quoted a lot, but the issue at hand was replacing the clutch master/slave cylinders, the brake master cylinder and the clutch/brake lines. After 3.5 months of the dealership working on my car, I got a call telling me my car is ready for pickup. Once I got there, I tested the clutch pedal and the travel distance didn't feel right. I started the car and attempted to enter a gear and it won't. It grinds first and reverse and simply will not enter 2-5.
The dealership washed their hands from the car saying I need to do more work: replacing the clutch, maybe the flex plate is broken, inspecting the transmission for possible broken parts. How can a driving vehicle be immobilized after replacing the clutch master/slave cylinders and the brake master cylinder? I have been disputing the service and charges from the dealership but I am looking to figuring out what possibly went wrong.
The most frustrating part of it is now my 928 doesn't drive and it will sit indefinitely. Which we all know will cause further deterioration.
Any insight from the experts would be appreciated.
Thank you,
Clyde
I have a 1984 928 5sp that I've been slowly working on catching up past due maintenance. All while regularly driving the car. 4 months ago, while driving the car, the clutch pedal went mushy. Since I was far from home and around a certified classics Porsche dealership, I figured it wouldn't hurt to check the car in with Porsche and have them look over the car.
I was quoted a lot, but the issue at hand was replacing the clutch master/slave cylinders, the brake master cylinder and the clutch/brake lines. After 3.5 months of the dealership working on my car, I got a call telling me my car is ready for pickup. Once I got there, I tested the clutch pedal and the travel distance didn't feel right. I started the car and attempted to enter a gear and it won't. It grinds first and reverse and simply will not enter 2-5.
The dealership washed their hands from the car saying I need to do more work: replacing the clutch, maybe the flex plate is broken, inspecting the transmission for possible broken parts. How can a driving vehicle be immobilized after replacing the clutch master/slave cylinders and the brake master cylinder? I have been disputing the service and charges from the dealership but I am looking to figuring out what possibly went wrong.
The most frustrating part of it is now my 928 doesn't drive and it will sit indefinitely. Which we all know will cause further deterioration.
Any insight from the experts would be appreciated.
Thank you,
Clyde
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- Rich928
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21 Oct 2024 10:07 #22763
by Rich928
Rich
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1993 928 GTS Cover Girl
1987 928 S4
1979 928 5-speed rescue
1979 928 5-liter track beast
Replied by Rich928 on topic 1984 5sp Won't Enter Gears
I found this post 928 OC Forum post from 2011 that may assist you.
Yes they work great however they will drag if not adjusted and maintained, the intermediate plate is held in place (floats) by three “finger like” links and they can become worn or get dirty and stick.
Devek had a great write up years ago, to put it simply; clean and use a dry lube on all three links and center the intermediate plate.
The clutch needs to be disengaged (open/peddle down) to do this.
Rotate engine until each link is at the bottom (clean lube) and center the intermediate plate, repeat two more times.
Some will say there is a measurement however that only would/could apply if all parts are new and most are not.
Yes they work great however they will drag if not adjusted and maintained, the intermediate plate is held in place (floats) by three “finger like” links and they can become worn or get dirty and stick.
Devek had a great write up years ago, to put it simply; clean and use a dry lube on all three links and center the intermediate plate.
The clutch needs to be disengaged (open/peddle down) to do this.
Rotate engine until each link is at the bottom (clean lube) and center the intermediate plate, repeat two more times.
Some will say there is a measurement however that only would/could apply if all parts are new and most are not.

Rich
Membership Chairman
Charter Member
1993 928 GTS Cover Girl
1987 928 S4
1979 928 5-speed rescue
1979 928 5-liter track beast
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- Rich928
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21 Oct 2024 10:22 #22764
by Rich928
If you need to have further service, the Porsche 928 clutch is relatively easy to remove, the torque tube doesn't need to be removed as in some other cars. The diagram above shows the components. Item #1, the central shaft, should be inspected. It and the clutch plates may just need to have the splines cleaned so they can smoothly move. Worst case it may need to be replaced. The clutch release bearing (aka "throw-out bearing") should be replaced if you open it up.
Rich
Membership Chairman
Charter Member
1993 928 GTS Cover Girl
1987 928 S4
1979 928 5-speed rescue
1979 928 5-liter track beast
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Replied by Rich928 on topic 1984 5sp Won't Enter Gears
If you need to have further service, the Porsche 928 clutch is relatively easy to remove, the torque tube doesn't need to be removed as in some other cars. The diagram above shows the components. Item #1, the central shaft, should be inspected. It and the clutch plates may just need to have the splines cleaned so they can smoothly move. Worst case it may need to be replaced. The clutch release bearing (aka "throw-out bearing") should be replaced if you open it up.
Rich
Membership Chairman
Charter Member
1993 928 GTS Cover Girl
1987 928 S4
1979 928 5-speed rescue
1979 928 5-liter track beast
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- Atour
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21 Oct 2024 17:11 #22765
by Atour
Replied by Atour on topic 1984 5sp Won't Enter Gears
Hi Rich,
I really appreciate the response and direction. If I'm understanding correctly, the intermediary plate should have been readjusted.
Thank you,
Clyde
I really appreciate the response and direction. If I'm understanding correctly, the intermediary plate should have been readjusted.
Thank you,
Clyde
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21 Oct 2024 17:17 #22766
by Rich928
Rich
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1993 928 GTS Cover Girl
1987 928 S4
1979 928 5-speed rescue
1979 928 5-liter track beast
Replied by Rich928 on topic 1984 5sp Won't Enter Gears
Hello Clyde,
I don't believe this "readjustment" is a factory specified type activity so the Porsche Classic shop wouldn't necessarily know about it. It is one that has been learned with experience and shared on the internet. It may help if all the parts are moving smoothly on the shaft splines.
If this process doesn't help, then clutch disassembly and replacement of worn parts is necessary.
I don't believe this "readjustment" is a factory specified type activity so the Porsche Classic shop wouldn't necessarily know about it. It is one that has been learned with experience and shared on the internet. It may help if all the parts are moving smoothly on the shaft splines.
If this process doesn't help, then clutch disassembly and replacement of worn parts is necessary.
Rich
Membership Chairman
Charter Member
1993 928 GTS Cover Girl
1987 928 S4
1979 928 5-speed rescue
1979 928 5-liter track beast
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- Atour
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22 Oct 2024 10:38 #22767
by Atour
Replied by Atour on topic 1984 5sp Won't Enter Gears
That makes sense. I appreciate your expertise Rich.
Thank you,
Clyden
Thank you,
Clyden
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