2003-2005 Cavalier Hydraulic Clutch Systems... SUCK! - Maintenance and Repair Forum

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2003-2005 Cavalier Hydraulic Clutch Systems... SUCK!
Monday, September 25, 2006 4:15 PM
So I've been having problems with my car's clutch pedal for about 3 months now... every so often it would get stuck on the floor and I'd have to pull it up and it would be fine for a few weeks... then I started to have a problem with it not doing anything at all for 3/4 of the pedal travel and then the clutch would disengage... Saturday night, I go to pull away when the light changed to green... I release the clutch... sticks to the floor... cars start honking... I pull the pedal up with my foot and push it down again... can't get it into gear... I COAST across 2 lanes of traffic with my caution lights on into a 7-Eleven parking lot where it sat until GM Roadside Assistance towed it away....

This afternoon... I get a call from my dealer... The clutch master cylinder has blown and needs to be replaced (under warranty thank god) but would have been in the neighborhood of ~$800 parts & labor.

It's not just me...

http://www.j-body.org/forums/read.php?f=11&i=73250&t=73250&arch=1#73250
http://www.j-body.org/forums/read.php?f=11&i=62708&t=62708&arch=1#62708
http://www.j-body.org/forums/read.php?f=11&i=63013&t=63013&arch=1#63013
http://www.j-body.org/forums/read.php?f=11&i=59014&t=59014&arch=1#59014
http://www.j-body.org/forums/read.php?f=11&i=54356&t=54356&arch=1#54356
http://www.j-body.org/forums/read.php?f=11&i=51439&t=51439&arch=1#51439
http://www.j-body.org/forums/read.php?f=11&i=49121&t=49121&arch=1#49121
http://www.j-body.org/forums/read.php?f=11&i=110712&t=110712#110712
http://www.j-body.org/forums/read.php?f=11&i=109929&t=109929#109929
http://www.j-body.org/forums/read.php?f=11&i=98437&t=98437#98437
http://www.j-body.org/forums/read.php?f=11&i=86811&t=86811#86811
http://www.j-body.org/forums/read.php?f=11&i=80769&t=80769#80769

The problems seem to be concentrated on 2003 to 2005 models... WTF was GM smoking when they designed this system? Why in the world didn't they do a recall?




Re: 2003-2005 Cavalier Hydraulic Clutch Systems... SUCK!
Monday, September 25, 2006 5:12 PM
From what I see on my car, a bracket that holds a large electrical connector is rubbing on the rubber line that connects the clutch master to the slave cylinder. My hose has a notch in it.



Re: 2003-2005 Cavalier Hydraulic Clutch Systems... SUCK!
Monday, September 25, 2006 8:52 PM
yep, same thing happened to me, but mine didn't get warrantied...

  

Re: 2003-2005 Cavalier Hydraulic Clutch Systems... SUCK!
Tuesday, September 26, 2006 4:31 AM
I just don't understand... are they just being cheap bastards?? what about the poor souls who had theirs die at 36500 miles??? Mine was at 25000... it's possible that it could have held out that long... they HAVE to know this is a problem...



Re: 2003-2005 Cavalier Hydraulic Clutch Systems... SUCK!
Tuesday, September 26, 2006 7:37 AM
That was posted here about 6 months ago. When i saw that i went and had a look at my clutch setup on my '03. It wasn't rubbing the brake lines like several other people's were. But i did do a little prevenatitve action. I took about a foot of 3/8" rubber fuel line and zip tied it to the clutch tube from the clutch master cylinder to the slave cylinder in the area of the hard brake lines. It will take a while to wear through that. GM got very cheap with these cars, especially after 2001.
Don
Re: 2003-2005 Cavalier Hydraulic Clutch Systems... SUCK!
Tuesday, September 26, 2006 8:19 AM
oh ok... i wish i saw that thread... so it is rubbing through, huh? I seem to have both major problems... the problem of the clutch cylinder dying and of the nasty dirt in the reservoir... I'm not sure if mine rubbed through though... they just told me they had to replace the whole system - meaning they had to drop the trans... hopefully they flushed the whole clutch system and got new fluid in there... I can't wait to feel the improvement...



Re: 2003-2005 Cavalier Hydraulic Clutch Systems... SUCK!
Tuesday, September 26, 2006 9:35 AM
I know of several people that had the rub-through problem, haven't had any personal experience with the nasty dirt in the reservoir with my local friends either. Guess i'm lucky, my reservoir is as clean as a whistle, and the section of hose & zip ties should help the rub through problem. I saw the potential for the rubbing when i installed my AEM CAI & Pacesetter ceramic header and did the zip tie/rubber line thing then while i was there. Next up is a cat-back, and 17" wheels/tires followed by a suspension lowering setup .
Don
Re: 2003-2005 Cavalier Hydraulic Clutch Systems... SUCK!
Tuesday, September 26, 2006 12:56 PM
::UPDATE::

The dealer says that the leaking fluid was coming from my throwout bearing and they replaced the entire clutch/pressure plate/throwout bearing assembly

So I got a brand new clutch under warranty!!



Re: 2003-2005 Cavalier Hydraulic Clutch Systems... SUCK!
Tuesday, September 26, 2006 1:37 PM
hahahahaha and you believed them? hahahaha.

A TOB doesn't have any fluid in it nor the clutch , the flywheel or the pressure plate.

Blown slave, bad rear main seal or tranny seal can leak but that is all.



Gilles
2.3 Ho

Re: 2003-2005 Cavalier Hydraulic Clutch Systems... SUCK!
Tuesday, September 26, 2006 11:54 PM
The slave is down with the throw out bearing on these cars. So if the slave leaks it highly likely the clutch got soaked in fluid and for these writers they seem to just kinda mix things up when they explain things in my experience.
My 04 had a leak from the resivor fluid looked like crap found out that was a failed seal in the resivor had that whole line assembly replaced under warranty also at 20k.


Re: 2003-2005 Cavalier Hydraulic Clutch Systems... SUCK!
Wednesday, September 27, 2006 6:50 AM
Many peoples problems are also from not having the floor mat pulled back, it likes to creep up and can cause the clutch pedal to get stuck.


-Chris


Re: 2003-2005 Cavalier Hydraulic Clutch Systems... SUCK!
Wednesday, September 27, 2006 8:43 AM
Mfk-223 wrote:hahahahaha and you believed them? hahahaha.

A TOB doesn't have any fluid in it nor the clutch , the flywheel or the pressure plate.

Blown slave, bad rear main seal or tranny seal can leak but that is all.


TOB = Slave cylinder and bearing in 1 piece.

Was the 800 bucks for the clutch assembly also? Or was that just strictly for the Master cylinder? Cuz if it's for the master cyl, that's a bit steep. I think doing it yourself it's like what.... 40 bucks? Plus a bottle of DOT3 Brake fluid.





Re: 2003-2005 Cavalier Hydraulic Clutch Systems... SUCK!
Wednesday, September 27, 2006 8:57 AM
Don Austin wrote:That was posted here about 6 months ago. When i saw that i went and had a look at my clutch setup on my '03. It wasn't rubbing the brake lines like several other people's were. But i did do a little prevenatitve action. I took about a foot of 3/8" rubber fuel line and zip tied it to the clutch tube from the clutch master cylinder to the slave cylinder in the area of the hard brake lines. It will take a while to wear through that. GM got very cheap with these cars, especially after 2001.
Don


Do you have a picture of this, I'm not sure what you mean.



Re: 2003-2005 Cavalier Hydraulic Clutch Systems... SUCK!
Wednesday, September 27, 2006 8:58 AM
I didnt look through the list , but that happened to me, and i had to fight with the dealer because suposidly my aftermarket intake ruined the clutch?


It was a hassle , and some b/s .







Re: 2003-2005 Cavalier Hydraulic Clutch Systems... SUCK!
Wednesday, September 27, 2006 9:04 AM
I must have a really good dealer... according to the service writeup, they replaced the clutch, pressure plate, throwout bearing and slave cylinder...

I have intake, exhaust and header and they didn't give me an ounce of problems about it...

apparently the throwout bearing is hydraulic on these cars and thats what blew... when it did, it spewed hydraulic fluid all over the clutch and pressure plate which apparently can't be cleaned off so they replaced that too...

of course when I got it back, i drove it for about an hour and then the dash guages started going all crazy so I pulled over and turned off the car... it wouldn't start back up... I popped the hood and looked around... they forgot to re-attatch a ground wire from the battery to the block when they put everything back together.

So I attatch it back up and everything is great now


Edited 1 time(s). Last edited Wednesday, September 27, 2006 9:06 AM


Re: 2003-2005 Cavalier Hydraulic Clutch Systems... SUCK!
Wednesday, September 27, 2006 12:41 PM
SHOoff wrote:
Mfk-223 wrote:hahahahaha and you believed them? hahahaha.

A TOB doesn't have any fluid in it nor the clutch , the flywheel or the pressure plate.

Blown slave, bad rear main seal or tranny seal can leak but that is all.


TOB = Slave cylinder and bearing in 1 piece.

Was the 800 bucks for the clutch assembly also? Or was that just strictly for the Master cylinder? Cuz if it's for the master cyl, that's a bit steep. I think doing it yourself it's like what.... 40 bucks? Plus a bottle of DOT3 Brake fluid.


Hum, Gm didn't really innovate when they desing that. I'll keep my TOB and forks with separate slave.

Sorry for the comment Tim.



Gilles
2.3 Ho

Re: 2003-2005 Cavalier Hydraulic Clutch Systems... SUCK!
Thursday, September 28, 2006 4:41 AM
no harm, no foul...



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