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Clutch drag can sometimes be the result of a distorted release arm, which flattens in use from it’s original shape. This causes the rear of the release bearing to foul on the release arm under full stroke of the pedal, restricting the travel of the release mechanism. Visual evidence of this complaint can normally be seen by contact marks on the top rear edge of the bearing, and the top edge of the aperture in the release arm, where the two components have fouled each other in use. In extreme cases, the free play in the release mechanism will be excessive, and there will be insufficient adjustment left on the slave cylinder pushrod to set to the correct dimension. Where this complaint has occurred, the release arm should be replaced to return the release arm to the original dimensions. Pushrod Location Foul Contact Point

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ISSUE A “soft” unresponsive clutch pedal may be felt or the driver may be unable to release the clutch. This is caused by air entrapped in the clutch hydraulic system. ACTION Use the information in this TSB article in addition to the appropriate bleeding procedure. This article includes detail as well as extra service tips for easier hydraulic clutch bleeding. The clutch hydraulic system for the 1993 model year is new and more difficult to bleed than the previous hydraulic system. Therefore, a different bleeding procedure is required for these vehicles. RANGER, EXPLORER, AEROSTAR The most difficult systems to bleed are on the Ranger, Explorer, Aerostars. NOTE: When installing dry clutch cylinder or tube service parts, do the bench bleed procedure first. BENCH BLEED The compact vehicles are more difficult to bleed because the downward angle of the master cylinder makes it difficult for air to escape up into the reservoir. Therefore, if the master cylinder is removed from the vehicle and bled while held in a vertical orientation (a bench bleed) air can escape much more efficiently. Refer to Fig. 1 . BENCH BLEEDING PROCEDURE (CONCENTRIC SLAVE CYLINDER) 1. Remove master cylinder, line and reservoir from vehicle and assemble with replacement parts required based on initial concern. 2. Hold the master cylinder vertically with the reservoir feed hose in the highest position on the body. See Fig. 1 . 3. Fill the reservoir and extend above the master cylinder and assure the quick connect on the clutch line is below the master cylinder. (Lightly clamp reservoir in a vise). 4. Using a small screwdriver, depress the internal mechanism of the male quick connect coupling to open the valve. See Fig. 1 . 5. Stroke and hold master cylinder pushrod. 6. Close quick connect valve. 7. Release master cylinder pushrod. 8. Fill reservoir. 9. Repeat Steps 4 through 8 four more times. 10. With the master cylinder still being held with the outlet tube and reservoir feed tube ends high, quick connect closed and the reservoir full, proceed as follows: a. Push the pushrod into the body several times quickly to expel any remaining air. b. If it is a remote reservoir, pinch the supply hose with your fingers two or three times to help move air into reservoir. 11. When the movement of the pushrod is .130″ (4mm) or less when stroked in Step 10, reinstall the master cylinder into the vehicle and couple it to the slave cylinder.

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Removal Procedure 1. Remove the clutch master cylinder pushrod from the clutch pedal. 2. Remove the master cylinder retaining nuts at the front of the dash. 3. Remove the remote reservoir. 4. Disconnect the clutch actuator cylinder line. 5. Remove the clutch master cylinder assembly from the clutch pedal assembly. Installation Procedure 1. Install the clutch master cylinder assembly to the clutch pedal assembly. 2. Connect the clutch actuator cylinder line. 2005 Chevrolet Cavalier L4-2.2L VIN F 3. Install the remote reservoir. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the master cylinder retaining nuts at the front of the dash. ^ Tighten the nuts evenly to 21 Nm (15 ft. lbs.). 5. Install the pushrod to the clutch pedal. 6. Bleed the hydraulic system.

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Hydraulic Clutch Control System IMPORTANT: The clutch hydraulic system is to be serviced as a COMPLETE UNIT!!!. It is a sealed unit and has been filled with fluid and bled of air at the factory. Individual components of the system are not available for service, except the slave cylinder actuator pushrod plastic retainer strap. Do not attempt to bleed the clutch hydraulic system. The bleed screw located on the clutch hydraulic slave cylinder is used for the factory fluid fill only. WARNING: Do not attempt to bleed the clutch hydraulic unit. Any observed fittings are there for factory use only. The unit comes as a complete pre-bled unit. REMOVAL 1. 2. 3. 4. 5. 6. 7. Block clutch pedal up to prevent pedal from being depressed with slave cylinder removed from transaxle. Remove air induction system. Disconnect negative battery cable from battery. Disconnect positive battery cable from battery Remove hold-down retaining nut and screw, and lift off battery hold-down retainer. Lift the battery of vehicle, and place in a safe location. Remove battery tray bolts and tray. IMPORTANT: One bolt is located in the fender well. NOTICE: Removal of the hydraulic damper with a power tool prior to removal of the actuator could result in breaking off the hydraulic line. IMPORTANT: Prior to removing the slave cylinder from the clutch housing, make sure that the clutch hydraulic system has sufficient fluid. Refer to the “Clutch Hydraulic Fluid Check” procedures in this manual. (This is not necessary if the clutch hydraulic system is being removed to be replaced.) 8. Rotate actuator 1/4 turn counterclockwise while pushing toward housing in order to disengage the bayonet connector and remove from clutch housing. 9. Remove two hydraulic damper to clutch housing nuts and slide damper and bracket assembly off studs.

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NOTE: It is necessary to bleed the clutch hydraulic release system if the system has lost an excessive amount of fluid and air has been introduced into the circuit. Air in the system typically results in a spongy pedal feel, and/or improper clutch release. If air cannot be removed from the system using this procedure, it is necessary to replace BOTH the clutch master cylinder and slave cylinder assemblies. From driver’s seat, actuate clutch pedal 60 – 100 times. Verify clutch operation/pedal feel. If pedal still feels spongy, or clutch does not fully disengage, excessive air is still trapped within the system. Perform the following procedure: 1. Verify fluid level in clutch master cylinder reservoir. Top off with DOT 3 brake fluid as necessary. 2. Raise vehicle on hoist. 3. 2.0L Models: Remove left lateral bending brace. 4. Remove clutch slave cylinder/damper assembly from the transaxle case (Fig. 5), but do not disconnect from the system. Allow the slave cylinder hang, making it the lowest part of the system. CAUTION: While slave cylinder is detached from the transaxle, DO NOT actuate the clutch master cylinder. Damage to the slave cylinder will result. 5. Depress slave cylinder pushrod until it bottoms and then release. Repeat this at least ten 10 times, forcing trapped air upwards and out of the system. 6. Re-install slave cylinder into position. 1.6L equipped models: Torque slave cylinder to case bolt to 12 Nm (105 inch lbs.) . 2.0L equipped models: Torque slave cylinder to case bolt to 19 Nm (168 inch lbs.) . Install and torque damper (if equipped) to case nuts to 24 Nm (215 inch lbs.) . 7. Lower vehicle.