M/T - Clutch Pedal Buzz/Vibration
Bulletin No.: 02-07-31-003BDate: March 10, 2004
TECHNICAL
Subject:
Clutch Pedal Buzz or Vibration (Replace Clutch Actuator Pipe)
Models:
2000-03 Chevrolet Cavalier
2000-03 Pontiac Sunfire
with Manual Transmission - RPOs M86 or M94
Supercede:
This bulletin is being revised to include newly designed parts. Please discard Corporate Bulletin # 02-07-31-003A (Section 07-Transmission/Transaxle).
Condition
Some customers may comment on a clutch pedal buzz or vibration usually felt during mid travel while releasing or engaging the clutch. This condition may also be noticed if the customer "rides" or rests their foot on the clutch pedal, which is not a recommended practice.
Cause
The natural engine harmonics or vibrations that can be felt through the clutch release system may cause this condition.
Correction
Replace the clutch actuator pipe using the procedure and part numbers listed below.
Important:
A new clutch actuator pipe, which includes a damper, has been developed to REDUCE BUT NOT ELIMINATE the vibration. Replace the clutch actuator pipe using the procedure and part numbers listed below.
1. Remove the air cleaner outlet duct.
2. Disconnect the battery cables and remove the battery.
3. Remove the relay center push in retainer.
4. Disconnect the relay battery feed cable from the upper air cleaner cover retaining clips.
5. Position the relay center away from the air cleaner assembly.
6. Remove the push in retainer from air cleaner assembly to the battery tray.
7. Remove the air cleaner assembly from the vehicle.
8. Remove the clip and disconnect the clutch actuator pipe from the master cylinder.
9. Remove the clip and disconnect the clutch actuator pipe from the actuator.
10. Remove the old clutch actuator pipe.
11. Install the new clutch actuator pipe, P/N 89058660, into position.
12. Connect the new clutch actuator pipe to the master cylinder and install the clip.
13. Connect the new clutch actuator pipe to the actuator and install the clip.
14. Install retaining bracket, P/N 12588319, with bolt, P/N 22598028, and nut, P/N 11514596, as shown above.
Tighten
Tighten the nut and bolt to 10 N.m (2.25 lb ft).
15. Slide the pin part of the air cleaner assembly into the bracket hole on the left strut tower.
16. Position and install the air cleaner inlet over the resonator neck.
17. Install the push in retainer from the air cleaner to the battery tray.
18. Install the relay center and the push in retainer.
19. Connect the relay battery feed cable into the upper air cleaner cover retaining clips.
20. Install the battery.
21. Install the air cleaner outlet duct.
22. Bleed the hydraulic clutch system.
Parts Information
Parts are currently available from GMSPO.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer