Installed new clutch; not getting enough pedal :-(

[jrsmith]

Hey guys,

I'm new to the forum here, check out my intro post on the introduction forum!

Anyways I've been having some issues with my 05 Pursuit after I swapped in a new clutch (I bought it for cheap because the clutch was gone).

I bought an exedy kit which included a new disk, pressure plate & throwout bearing/slave cylinder. Also made sure to get the flywheel turned. Put it all back together, bled the clutch multiple times using both the traditional two person bleed method & the top vacuum method...but the clutch is still partially engaged when I put the pedal all the way down to the floor, i.e. with clutch pedal down, when I put it in first the vehicle will start to roll forward a bit.

Just yesterday I tried swapping out the master cylinder with another one from a junk yard but that made almost no difference, I did get a bit more clutch disengagement but not much.

At this point I am thinking of maybe two things: machine shop turned the flywheel too much, or maybe a defective slave cylinder?

Any thoughts would be very much appreciated. I've spent so many hours on this and I still can't drive it! :-(

 

[YelloEye]

Both of those things are possible. You can check into getting an adjustable clutch rod. Think zzp makes one.

 

[jrsmith]

Thanks for the info about that clutch rod, sounds like it might work as I just need a bit more reach. A bit pricey though. Too bad these cobalts have no adjustment capability. I think i'm going to go on the assumption that the flywheel has been machined too much and get a good used from a junker. Only $75 so not too bad. I'll test the slave cylinder while I have the tranny out.

 

[YelloEye]

I would guess that the slave is bad or your flywheel is low. You shouldn't need that much travel. Did you make sure the clutch rod is straight? I've heard of them bending.

 

[onedoughboy]

I don't think the machine shop could take enough off for you to not be able to disengage the clutch. You should check the rod leaving out of the clutch pedal. The rod should move right away. There's a plastic piece in there that could be damaged allowing the pedal to move before moving the rod(the pedal has its own spring, which makes it come all the way back up). Also using a clear tube over the bleeder, then back to the brake reservoir, pump the pedal tell you see nothing but fluid. It's a pain to work on the pedal under the dash. I would recommend removing the steering column, if you need to work on the pedal. Some people that remove the pedal assembly, put it back together wrong. Another quick note, the dealership clutch kit is about $190. You may have the wrong kit for the vehicle. My friend just got a clutch kit from AUTOZONE and the slave cylinder was wrong. Happens.

 

[jrsmith]

Well the Cobalt flywheel is apparently NON SERVICEABLE, and should never be machined...I am waiting for 100% confirmation of that fact though. One thing to be sure, there is absolutely zero adjustment capability on these cars, so it makes sense to me that you wouldn't want to mess with the flywheel.

The rod from the pedal is fine...I already tried swapping in another clutch master cylinder from a low mileage wreck, didn't change a thing.

I've already tried a couple different bleeding methods, nothing really made any difference. I had a friend come over and we did the old fashioned "push the clutch pedal down, open the bleeder, etc". After that I bought a vacuum bleeder and followed a gm document on how to do it via vacuum. No difference.

I'm pretty sure the clutch disk, pressure plate & slave cylinder are correct...they all look exactly the same as the ones I pulled out, everything fit together nicely. I paid $325 CDN including shipping and customs from the US. Do you have a part # for the dealer clutch kit?

 

[YelloEye]

Check on crateenginedepot.com they have the parts you need.

 

[jrsmith]

Thanks. I picked up another flywheel yesterday, we'll see if that fixes my problem. Cradle going down tonight!

 

[Bass_Waves]

Wait. Is it a Cobalt or a Pursuit. What was the Pursuit. I remember a car like that??????

---------- Post added at 10:22 AM ---------- Previous post was at 10:20 AM ----------

If its a cobalt and clutch. That's my thing. I do them here and there for extra cash lol.

 

[YelloEye]

Wait. Is it a Cobalt or a Pursuit. What was the Pursuit. I remember a car like that??????

---------- Post added at 10:22 AM ---------- Previous post was at 10:20 AM ----------

If its a cobalt and clutch. That's my thing. I do them here and there for extra cash lol.

It's a 2005-2006 G5 in Canada.

Chevrolet Cobalt - Wikipedia, the free encyclopedia

A Pontiac version was sold primarily as the Pontiac G5 in Canada for its entire run (where it was briefly known as the Pontiac Pursuit and later Pontiac G5 Pursuit), as well as the Pontiac G4 in Mexico for 2005–2006, and in both Mexico and the United States under the G5 name for 2007–2009. In all cases, the G5 replaced the Cavalier-related Pontiac Sunfire. While the Cobalt was available as a 2-door coupé and a 4-door sedan in all markets it was offered in, the G5 was only available as a coupé in the United States while a sedan version was sold alongside the coupé in Canada and Mexico.