04 Aveo clutch pedal goes to floor

[DRG2003]

It's been a while, but from what I remember it was pretty simple. Remove the battery and battery tray for easy access from the top. The shift linkage was kind of a pain, but just follow the points it connects to the transmission and unbolt. I do remember I removed the whole C shaped bracket that a lot of the linkage was held to, and just let that hang while I dropped the transmission. That bracket was held in by 3 or 4 bolts.

I think there are only 2 or so wiring connectors, maybe one for the backup lights and one for a speed sensor?

Oh, and the gear oil will spill out when you pull the axels out, so you'll want to have a container handy and some more gear oil. Good time to actually fully drain it and clean the little magnet on the drain plug. If I remember right I just unbolted the ball joints and tie rod ends to allow the strut assembly so swing out enough to pull the axels out.

Unless you know your clutch is really decent, I'd recommend just ordering a clutch kit while you're at it and getting it over with. You'll literally have the whole transmission out at this point just like you'd have to do with a clutch job. Do you really want to have to drop it again sometime soon down the road? I wasn't about to gamble that! You can get a whole clutch kit on eBay for under $100. Parts are super cheap for these cars.

[Amoros]

Thank you for the information, I really appreciate it.

[Ed6137]

Hey guys I'm having the same problem I have a 2008 Aveo I replace the slave cylinder my clutch pedal also went to the floor I put it in and now the clutch pedal is very hard it does not want to go back down I don't understand is there something that I am missing or not understanding about this is it something easy and simple please if you've had this problem and got past it please email me eddietierney515@gmail.com

[DRG2003]

Just e-mailed you this is case you don't check back here:

Sounds like you had the same problem I had. The shift lever in the transmission bent. This is the lever that the slave cylinder pushes against when you push the clutch pedal in. The lever isn't pushing back against the slave cylinder (because it's bent), so the slave cylinder is already all the way out, giving you the hard clutch pedal. If you push on the pedal too hard, you'll blow the slave cylinder seal out and need to replace that again.


The bad news is, to replace that clutch lever you have to drop the transmission. The good news is it's not terribly hard if you've done anything like that before, the part isn't expensive, and you might as well do a clutch job while you're in there since a whole kit is only around $100.


Good luck!

[milesvinson]

I recommend replacing the clutch release lever and fork whenever you do a clutch job on Aveos. It seems to be a common failure and will drive you nuts trying to figure it out when the lever "bends". It may appear fine like mine did, but the lever shifted or bent in the weld even though it appeared fine. This will prevent the clutch pedal from being fully pressed to the floor. Many times it will end up with you blowing out the slave cylinder. Both parts are less than $50 US dollars. Changing them while you already have the transmission out will save you from having to drop the transmission again. If your parts are fine, change them anyway. It may prevent a costly and inconvenient tow bill later. I believe the part numbers for 2004-2008 Aveos are as follows:

Part No.: 96144874 = LEVER

Part No.: 94580796 = FORK

[viciousvîc]

Curiosity asks? what was cause of bent clutch lever? For the next person who has clutch issues, my 2000 chevy metro @ around 200k miles lost pedal pulling into bros driveway, nothing, pedal stayed on floor. Lever was fully released, but clutch was still engaged. Pondering couple minutes, decided to drive home...50 miles...only two stop lights in my way before nonstop highway. Power shifting to forty mph gliding threw first light with ease, coasted to a stop for second one. Green light she started up bucking, lil fuel n second gear off to races....long story short...clutch disc spring somehow got wedged between disc n flywheel, leaving zero clearance for any play. Replaced disc with OEM , on the road again. Never heard of a disc losing a spring n wedging clutch inoperable ...crazy stuff....bent lever? hydraulic slave? figured blow seals n piston before bending lever. Always first time for everything. ps, still have metro, 478,883 miles, burnt valve , but she still runs. on bloks now since '18. new head waiting for Aveo5 to hit 200k scheduled maintenance june next year, 25k mi. to go...