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Applications and Greasing Specifications




CLUTCH BOOST SPRING: ALLOCATION AND GREASE SPECIFICATIONS
1. Boost Spring Bracket Allocation
1.1 Boxster Before Model 1998
- The bracket for the boost spring cannot be unscrewed.
1.2 Boxster As Of Model 1998
- Silver bracket and boost spring with white marking must be used only in this combination and installed only in the Boxster (refer to the parts supplier for the correct variations).





NOTE:
- The gold-colored bracket and boost spring with purple marking are assigned to the 911 Carrera (996) and must not be installed in the Boxster.





2. Standard Boost Spring Allocation
2.1 Boxster Up To Model 1998
(boost spring bracket cannot be unscrewed)
Boost spring No. 1.
- Dimension X approx. 39 mm.
- Boost spring push rod open on one side.
- Observe replacement procedure and grease specification.
2.2 Boxster Model 1998 Partly Model 1999
(boost spring bracket can be unscrewed)
Boost spring No. 2.
- Dimension X approx. 42 mm.
- Boost-spring push rod open on one side.
- Boost spring with white marking.
- Observe replacement procedure and grease specification.
2.3 Boxster From Current Model 1999
(boost spring bracket can be unscrewed)
Boost spring No.3.
- Boost-spring push rod of closed.
- Boost spring with white marking.
- Observe grease specification (do not lubricate boost spring).
3. Boost Spring: Replacement Procedure
3.1 Boxster Before Model 1998
(boost spring bracket cannot be unscrewed)
- The standard boost spring No.1 (shown in step 2 above)
The original boost spring (1) is no longer available after existing supplies are used up.
The new version (2) boost spring will be used as a replacement.
This boost spring has a closed push rod and should not be lubricated.





Identifying feature: All-round green ring on the boost spring housing (arrow).
The bolt and the fuse for connector to the previous clutch pedal are included in the scope of delivery of the boost spring.
3.2 Boxster Model 1998 Partly Model 1999
(boost Spring bracket can be unscrewed)
- The standard boost spring No. 2 in illustration shown with step 2 above, (push rod on boost spring is open on one side) is no longer available after existing supplies are used up.
- The boost spring No.3 in illustration shown with step 2 above, will be used as a replacement (closed push rod / boost spring painted white).
This boost spring should not be lubricated.





- When the boost spring No. 3 in illustration shown with step 2 above, is installed for the first time, the optimized clutch pedal must also be used.

NOTE:
^ The hexagon bolt and the fuse for connection to the optimized clutch pedal are included in the scope of delivery of the boost spring.
^ This corresponds to the same scope as for the boost spring version No. 3 (from current Model 1999).

3.3 Boxster From Current Model 1999
(boost spring bracket can be unscrewed)
- The boost spring No. 3 (shown in step 2 above) is used as standard and in the event of replacement.

4. Grease Specification
It is essential to observe the following grease specification during assembly work on the pedals.





4.1 Pedal Bearing Axle
- Lubrication required in most cases. Grease the bearing bushings marked X and the. pedal bearing axle with Optimol, Optitemp LG 2.
4.2 Push Rod Of Clutch Master Cylinder
- Do not grease, as this could cause damage.
4.3 Spring Boost Area
- Lubrication may be required or prohibited, according to the spring boost version.
- In general, the following applies: Do not grease coated components, as this erodes the coating.
4.3.1 Boxster Up To Model 1998
(boost spring bracket cannot be unscrewed)
- A. Standard boost spring: Push rod open on one side. Component not coated.
Grease pin for boost spring with mating bearing on the boost spring push rod, the boost spring bearing and the bearing pins on the boost spring with Optimol, Optitemp LO 2.
First remove old grease with suitable solvent.
- B. Spare part replacement boost spring identifying feature:
Closed push rod and an all-round green ring on the boost spring housing.
Do not grease any areas as the components are coated.





4.3.2 Boxster Model 1998 Partly Model 1999
(boost spring bracket can be unscrewed)
- A. Standard boost spring:
Push rod open on one side.
Component not coated.
Grease pin for boost spring (arrow) with mating bearing on the boost spring push rod, the boost spring bearing (arrows) and the bearing pins on the boost spring with Optimol, Optitemp LG 2.
First remove old grease with suitable solvent.
The boost spring and the boost spring housing are greased with a special grease on the inside.
This grease is not available as a spare part.
Replace the entire boost spring (with boost spring housing) if necessary.
- B. Spare part replacement boost spring (version as from current Model 1999, illustration shown with step 3.2 above).
- Identifying feature: closed push rod and hexagon nuts for connection to the clutch pedal.
- Do not grease any areas as the components are coated.





4.3.3 Boxster From Current Model 1999
(boost spring bracket can be unscrewed)
- Push rod closed / connection to clutch pedal with a hexagon bolt.
- Do not grease any areas as the components are coated.
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