Clutch Pedal Spring

Clutch boost spring: allocation and grease specification
1. Boost spring bracket allocation
1.1 Boxster before Mod. '98
The bracket for the boost spring cannot be unscrewed.
1.2 Boxster as of Mod. '98
Silver bracket (986,423.571.00) and boost spring with white marking (986.423.081.08 or 986.423.081.11 / see boost spring allocation) must be used only in this combination and installed only in the Boxster.





Note The gold-coloured bracket (996.423.571.00) and boost spring with purple marking (996.423.081.09 or 996.423.081.11) 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 Mod. '98 (boost spring bracket cannot be unscrewed)
Boost spring No. 1. Dimension X approximately 39 mm, Boost-spring push rod open on one side. Observe replacement procedure and grease specification.
2.2 Boxster Mod. '98 partly Mod. '99 (boost spring bracket can be unscrewed) Boost spring No. 2. Dimension X approximately 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 Mod. '99 (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 Mod. '98 (boost spring bracket cannot be unscrewed)
The standard boost spring No.1 (Fig. 46998) Spare Part No. 986.423.081.07 is no longer available after existing supplies are used up. The boost spring 986.423.081.12 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 999.423.315.06 and the fuse 999.166.075.02 for connection to the previous clutch pedal are included in the scope of delivery of the boost spring.
3.2 Boxster Mod. '98 partit Mod. '99 (boost spring bracket cannot be unscrewed)
The standard boost spring No. 2 (push rod on boost spring is open on one side) Spare Part No. 986.423.081.08 is no longer available after existing supplies are used up.





The boost spring No.3 986.423.081.11 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 is installed for the first time, the optimised clutch pedal 996.423.139.09 must also be used.

Note The hexagon bolt 999.423.315.06 and the fuse 999.166.022.02 for connection to the optimised 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 Mod. '99).

3.3 Boxster from current Mod. '99 (boost spring bracket can be unscrewed)
The boost spring No. 3 (Fig. 46998) 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, Part No. 000.043.203.37.
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 Mod. '98 (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 LG 2, part No. 000.043.203.37. First remove old grease with solvent naphtha.
B. Spare part replacement boost spring Spare part No. 986.423.081.12
Identifying feature: Closed push rod and an all-round green ring on the boost spring housing. Do not grease any areas as the components a re coated.
4.3.2 Boxster Mod. '98 partly Mod. '99 (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, part No. 000.043.203.37. First remove old grease with solvent naphtha.





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 Spare part No. 986.423.081.11 (version as from current Model '99 / Figure 46798). 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 Mod. '99 (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.