How to fix the clutch pedal hanging problem

Information update: June, 2002

The clutch pedal hanging problem has been plaguing many 993 owners for number of years now, and there are also several different fix option that have risen.  Below is a sequential list of steps to take care of this problem, if the prior step does not fix the problem proceed with the next step (arranged based on repair cost)

(1). Try to lub the clutch pedal mechanism detailed in this DIY
(2). Flush the clutch slave cylinder Click here for DIY procedure
(3). Replace the clutch slave cylinder Click here for DIY procedure
(4). Perform the clutch pedal kinematics technical bulletin update.  Click here for DIY procedure

Caution: Some of you that are suffering the pedal hanging problem may have a different cause. This solution may not be the only solution to the clutch pedal hanging problem.

Symptom:  The clutch pedal does no return all the way up after it is released.  The last 2 inches of travel when released is very rough and sticky. 

Solution: The piston inside the clutch pedal assembly can sometime be expose to dust and dirt causing friction on the piston travel.  I cleaned the piston and lubricated all the connecting linkage and used lithium silicon grease to grease the piston rod. 

Aftermath: The pedal felt smoother and it returned to the original position after it was released without any assistance.

Step 1:  Remove the floor mat.  A plastic round screw holds the carpet in place to the floor pan.  Turn it counter clockwise to loosen the plastic bolt and remove it.

Step 2: Remove the carpet underneath the pedals will expose the wooden floor board that covers the pedal assembly.

Step 3:  There are 3 philips screws that holds the wooden floor board in place near the bottom of the floor board, you will need to pull back the carpet to see them.  There is one screw that is hidden underneath the gas pedal, you will need to pull the gas pedal off it's socket to get to that screw.  Just pull the gas pedal away from the top of the pedal will release it from the ball socket.

Step 4: From this point on everything could be different from car to car and problem to problem.  I want to show the pictures of where I cleaned and applied grease to.   I did notice that the protective rubber boot for the piston assembly was cracked and that was how dirt got into the piston.  Besides cleaning the piston rod and greasing it, I also lubricated all the linkage associated with the clutch pedal assembly.

To install everything back should be very straightforward with the exception of pushing the gas pedal back to it's connecting socket.  It is hard to exert force on the gas pedal and expecting it to stay.  The function of the gas pedal is for you to push upon it, and pushing it all the way down will not give you enough leverage to push the rod back into its socket.  After playing with damn thing I figured out in order for the gas pedal connecting rod to stay I need to wedge a screw driver underneath the connecting rod as a leverage for the gas pedal to push against. 


Tom Randel have some input about the gas pedal, sounds like an easier way to do this.  Here is his suggestions. 
 I've found that I can release the gas pedal by completely unscrewing the height adjustment screw.  Just undo the lock nut, then unscrew.  The ball swivels 360 degrees in the socket.  It's real easy to put it back in.  I've never tried to pull the ball out of the socket, but the description sounds harder than unscrewing the height adjustment screw.  You can also customize the throttle height this way. Just don't put it too low or the "stop" on the back of the pedal will hit the floor board before WOT.

I have found when replacing the pedal to the little arm, it is easier if you grab the arm with a pair of Visegrips then push the pedal against the hole. A little grease on the ball part of the arm helps also
Gary Bayless


Donor car for this DIY: John Chung's 95 993.
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