M/T - Grinding Noise When Clutch is Released
Bulletin No.: 03-07-31-005Date: October 30, 2003
TECHNICAL
Subject:
Grind Noise from Manual Transmission When Clutch Is Released (Replace Clutch Actuator Pipe)
Models:
2003-2004 Chevrolet Cavalier
2003-2004 Pontiac Sunfire
with Manual Transmission (RPO M86 or M94)
VIN Breakpoints
Condition
Some customers may comment on a grind noise from the transmission when the clutch is released all the way, clutch pedal pushed all the way to the floor.
Cause
A over travel condition of the clutch could cause a clutch finger to clutch disk interference that may emit a grinding type noise transmitted through the clutch actuator pipe to the clutch pedal to the driver's foot.
Correction
A new clutch actuator pipe which includes a damper has been developed to reduce the vibration and noise. Replace the clutch actuator pipe using the procedure and part numbers listed below.
Important:
DO NOT REPLACE the following clutch components. They WILL NOT correct this condition.
^ P/N 90537283
^ P/N 22629291
^ P/N 22629292
^ P/N 12578064
^ P/N 12578156
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 the 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 12580748, into position. The actuator pipe includes the entire master cylinder.
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 Nm (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