SaturnFans.com
what's new (beta) - classifieds - forums - photos


Go Back   SaturnFans.com Forums > Categories > How-To Library
Register FAQ Members List Groups Calendar Chat Room Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Display Modes
Old 11-01-2009, 01:37 AM   #1
ShawnV
Master Member
ShawnV is a jewel in the roughShawnV is a jewel in the roughShawnV is a jewel in the roughShawnV is a jewel in the rough
 
ShawnV's Avatar
 
Join Date: Aug 2007
Location: Greensboro, NC
Posts: 2,680
 

2000 SW2
Default How To: Clutch Hydraulic system with pics

Hereís a how-to on replacing the clutch hydraulics in a Saturn S-Series.

Iíd like to thank SLCraig for his help with this repair.

First, block up the clutch pedal so it cannot be depressed. I used a bungee cord.
Remove the air box and battery.
Remove the battery tray



There are three bolts to the battery tray Ė two on top and one on the drivers wheel well.



Next, remove the two bolts holding the clip on the slave cylinder.



Remove the slave cylinder by pushing in on it and turning counterclockwise until it pops out.

Let it hang there and move to the brake cylinder. Remove the two bolts holding the brake master cylinder to the booster.





Pull the brake cylinder off the bolt studs and move it towards the passengers side slightly. This gives room to get to the clutch master cylinder.

Now itís time to remove the clip holding your clutch pedal to the master cylinder pushrod. Get your light and a flathead screwdriver. Stand on your head looking up under the clutch pedal and youíll see a clip. In the picture below the pushrod is silver with red paint on it. Itís connected to the clutch with a clip.



Remove the clip with your screwdriver and pull the pushrod off the stud on the clutch pedal.



Hereís a picture of the clip that holds it on:



Let the push rod hang there and return to the engine bay. Next grab the master cylinder and turn 1/8th of a turn counterclockwise and pull it out of the dash. The push rod will pull out as well. Note the brake master cylinder off its studs and moved aside in the pic below:



Take note of how the hydraulic lines are run under the brake lines and other stuff as you try and untangle it. I pulled the master cylinder under all that stuff and put it back in the same way.

Hereís a picture of the clutch hydraulics:
Left to right is pushrod/master cylinder and then slave cylinder. The slave cylinder pushrod was not present in the picture!



Notes:

This took me about 30 minutes on my first time doing it.

There is a clip holding the pushrod on the slave cylinder side that holds the rod in place while installing the slave cylinder. The first time you push the clutch youíll break this retaining clip. Itís normal.

If you run into very much resistance after ever removing the slave cylinder STOP. Donít stand up on the clutch because you will blow out the slave cylinder. Itís possible for the slave pushrod to miss the clutch fork and give you a rock solid clutch pedal.

REWARD EXCELLENCE!

Add to ShawnV's Reputation
Rate the quality of this post and help ShawnV reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
ShawnV is offline   Reply With Quote
SaturnFans.com Sponsored Links
Old 11-01-2009, 11:12 AM   #2
Signmaster
Master Member
Signmaster is a splendid one to beholdSignmaster is a splendid one to beholdSignmaster is a splendid one to beholdSignmaster is a splendid one to beholdSignmaster is a splendid one to beholdSignmaster is a splendid one to beholdSignmaster is a splendid one to behold
 
Join Date: Jan 2007
Location: Virginia Beach, VA
Posts: 6,215
 

1995 SL1
Default Re: How To: Clutch Hydraulic system with pics

Good write up. This should be added to the How To library if the same isn't already in there.

REWARD EXCELLENCE!

Add to Signmaster's Reputation
Rate the quality of this post and help Signmaster reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
Signmaster is offline   Reply With Quote
Old 11-01-2009, 12:34 PM   #3
Low Saturn
Super Member
Low Saturn is a splendid one to beholdLow Saturn is a splendid one to beholdLow Saturn is a splendid one to beholdLow Saturn is a splendid one to beholdLow Saturn is a splendid one to beholdLow Saturn is a splendid one to beholdLow Saturn is a splendid one to behold
 
Low Saturn's Avatar
 
Join Date: Aug 2003
Location: San Jose, CA
Posts: 15,299
 

2000 SC2
Default Re: How To: Clutch Hydraulic system with pics

Just a couple things to add:

-There are four bolts securing the battery tray on older models.
-Theres a 10mm nut attaching the battery strap on the drivers side. No need to bend it and mess it up.
-Not necessary to mess with the brake brake master cylinder. On ABS or non-ABS models.

...
Mike

-1991 Turbo SL2.
11.809 @ 116.488 mph
www.differentracing.com

-2000 SC2
-2001 Limited Edition SC2 (#78)
-2001 Chevrolet Suburban
-2011 Rally Yellow Chevrolet Camaro 2SS RS

REWARD EXCELLENCE!

Add to Low Saturn's Reputation
Rate the quality of this post and help Low Saturn reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
Low Saturn is offline   Reply With Quote
Old 11-01-2009, 01:07 PM   #4
PurdueGuy
Master Member
PurdueGuy is a jewel in the roughPurdueGuy is a jewel in the roughPurdueGuy is a jewel in the rough
 
PurdueGuy's Avatar
 
Join Date: Feb 2005
Location: Blackfoot, ID
Posts: 6,483

1999 SC2
1999 SC1
Default Re: How To: Clutch Hydraulic system with pics

yeah, couple extra steps in there I wouldn't worry about (bungee on pedal, undoing brake master). Heck, I didn't even take out the battery tray the last couple times. I just remove intake & battery, undo clip on pedal & take the rod off the pedal, undo 2 nuts holding the puck, twist & remove both ends, maneuver it out, install reverse of removal.

...
SaturnSeries.net owner

REWARD EXCELLENCE!

Add to PurdueGuy's Reputation
Rate the quality of this post and help PurdueGuy reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
PurdueGuy is offline   Reply With Quote
Old 11-01-2009, 01:16 PM   #5
SLCraig
Master Member
SLCraig is on a distinguished road
 
Join Date: Aug 2007
Location: London, ON
Posts: 3,077

1996 SL2
2000 SW2
Default Re: How To: Clutch Hydraulic system with pics

ShawnV is a regular richpin !

FWIW, I noticed you have ABS. On a non-ABS car you can easily skip the undoing of the master cyl, it was no issue on my non-ABS car.

Super easy job, I was surprised how little effort it was. Chalk another one up for the Satty, such awesome easy cars to work on.

...
1996 SL2 5MT
1997 SL1 5MT
2000 SW2 5MT
All gone, but not forgotten.

REWARD EXCELLENCE!

Add to SLCraig's Reputation
Rate the quality of this post and help SLCraig reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
SLCraig is offline   Reply With Quote
Old 11-02-2009, 12:27 PM   #6
SaturnJon
Junior Member
SaturnJon is on a distinguished road
 
SaturnJon's Avatar
 
Join Date: Aug 2008
Location: Rice Lake, Wisconsin
Posts: 20

2000 SL
Default Re: How To: Clutch Hydraulic system with pics

Awesome write up! The pictures are very nice and everything is easy to see.

The only part I am confused on is the comment to ignore the master cylinder step if you have non-ABS.

I have non-ABS SL. Please explain about skipping this.

Thanks,

Jon

...
2000 Saturn SL, 108,000 miles

REWARD EXCELLENCE!

Add to SaturnJon's Reputation
Rate the quality of this post and help SaturnJon reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
SaturnJon is offline   Reply With Quote
Old 12-22-2011, 04:01 AM   #7
homiemitchell
Member
homiemitchell is on a distinguished road
 
Join Date: Dec 2011
Location: us, vermont
Posts: 81

2001 SL1
Default Re: How To: Clutch Hydraulic system with pics

ok will the clutch from a 96 work with 2000. or are they different?

REWARD EXCELLENCE!

Add to homiemitchell's Reputation
Rate the quality of this post and help homiemitchell reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
homiemitchell is offline   Reply With Quote
Old 03-24-2012, 05:47 PM   #8
October Red
Junior Member
October Red is on a distinguished road
 
October Red's Avatar
 
Join Date: Sep 2009
Location: Chepachet, RI
Posts: 43

2002 SC1
Default Re: How To: Clutch Hydraulic system with pics

This is a wonderfully useful thread. Today, my clutch stopped functioning. Using techniques learned in my Tao training, I visualized getting every light green on the 20 miles journey back to the safety of my house and my very own tools. And I did!

It took about 13 seconds to determine that the battery negative cable had been wearing on the plastic clutch hydraulic line under the battery box for the past 10 years and had worn a pinhole in it.

Then I found this thread, where I discovered that this is a sealed system with "no user serviceable parts" as they say on electronics these days. So I opened a new tab, skipped right on over to Rock Auto.com and ordered up a brandy new system. $93 including shipping. God I love the internet.

Then I went out and removed the old system in about 30 minutes. The only issue I had with the instructions in this thread is that the clutch master must be turned CLOCKWISE as you are looking at it while draped over the left front fender. The instructions say to turn it Counterclockwise, and that is true, if you are looking at the master cylinder from the driver's seat. But you're not. You are outside staring back at the firewall and if you try to turn it counterclockwise, you will soon be cursing like a drunken sailor.

So......to keep your sanity and protect the tender ears of any children who may be within hearing distance - roughly a mile or two - turn it clockwise and be a happy camper. Righty tighty, lefty loosey may pertain to Saturn clutch hydraulics, but, in the case of the clutch master cylinder, only if you are looking at the problem backwards.

Other than that one minor issue, a fantastic thread. I would never have attempted this on my own without it. And sure as shootin', I would have broken the battery support bracket if you guys didn't tell me about that bolt through the fender well!

Thanks

...
Ignorance can be cured with information. There is no cure for stupidity.

REWARD EXCELLENCE!

Add to October Red's Reputation
Rate the quality of this post and help October Red reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
October Red is offline   Reply With Quote
Old 06-04-2012, 10:59 PM   #9
DurhamBull
Junior Member
DurhamBull is on a distinguished road
 
Join Date: Jun 2008
Location: Durham, NC
Posts: 17

1997 SC2
Default Re: How To: Clutch Hydraulic system with pics

I'll add my sincere thanks for this guide which saved me about $17000 because I was going to buy a new car if the clutch in my old Saturn was shot. With the new hydraulics it shifts much better.

Here's my notes from the experience as an individual who knows exactly enough to get himself in trouble when it comes to vehicle repair.

When I got to the step of removing the slave cylinder by pushing on it, I didn't realize how hard I'd have to push to get it to come loose. I doesn't help that it's a slightly awkward angle at which to push which means I didn't have full leverage.

It wasn't until I got the slave cylinder out that I realized I'd ordered the wrong part from Rock Auto. (My fault, not theirs.) They sell the hydraulic hose by itself for $95 and the hose plus slave and master cylinders for anywhere from $76 - $110 depending on who makes it. I needed the Clutch Master and Slave Cylinder Assembly for my '97 SC.

With regards to the great controversy over whether or not to move the brake master cylinder when installing, I don't think it has anything to do with the size of one's hands. I've got long, skinny, agile fingers and I still couldn't get the new unit threaded into place on my non-ABS vehicle without moving the brake master cylinder. It's probably easier to install the unit with the hose going *above* the brake lines, but that looked to me like an invitation for damage to the line from a rubbing battery cable once everything gets back into place. The unit I replaced was original and it was threaded below the brake lines, and that's how I installed mine.

Also some mistakes not to make that I --- er, that a friend of mine made when he was doing this. While you're upside down under the dash removing the clip that connects the master cylinder pushrod to the clutch pedal, bear in mind that that little clip is yearning for freedom and will make the most of its opportunity. With one hand holding the flashlight and the other holding the screwdriver, you'll need your third hand to make sure it doesn't get too far.

Also, my friend -- this guy is really an idiot, you have to understand -- when reversing the process after the new unit was installed, he reattached the pushrod/clutch pedal clip and decided to test the linkage while he was down there. This promptly broke the factory-installed, one-use plastic binding on the slave cylinder which should only be broken once the cylinder is mounted in place which of course this one wasn't. Fortunately it was a gentle test and it didn't shoot the slave cylinder pushrod onto the driveway, thus saving the pusher a great deal of time, money and embarrassment.

First gear is no longer a constant trial, and I and everyone who has gotten stuck behind me at a traffic light is grateful for that.

REWARD EXCELLENCE!

Add to DurhamBull's Reputation
Rate the quality of this post and help DurhamBull reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
DurhamBull is offline   Reply With Quote
Old 06-09-2012, 05:12 PM   #10
ShawnV
Master Member
ShawnV is a jewel in the roughShawnV is a jewel in the roughShawnV is a jewel in the roughShawnV is a jewel in the rough
 
ShawnV's Avatar
 
Join Date: Aug 2007
Location: Greensboro, NC
Posts: 2,680
 

2000 SW2
Default Re: How To: Clutch Hydraulic system with pics

It sounds like you learn like I do...by making mistakes and then noting them!

I'm glad the how-to was useful.

REWARD EXCELLENCE!

Add to ShawnV's Reputation
Rate the quality of this post and help ShawnV reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
ShawnV is offline   Reply With Quote
Old 04-06-2016, 04:24 PM   #11
demoncamber
Member
demoncamber is on a distinguished road
 
Join Date: Apr 2009
Posts: 262

1997 SC2
Default Re: How To: Clutch Hydraulic system with pics

Does this fix the issue where it's hard to get into 1st gear and reverse at times?

...
///M5sc2-126k-5spd-Eagle GT's
-2x Alpine TypeS 12in 1223D -Kenwood KAC8104D -Audiobahn A4401T
-Alpine SPS-600c - Infinity Kappa 62.9I - 1.5f Cap

REWARD EXCELLENCE!

Add to demoncamber's Reputation
Rate the quality of this post and help demoncamber reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
demoncamber is offline   Reply With Quote
Old 06-03-2016, 04:51 PM   #12
marsneptune
New Member
marsneptune is on a distinguished road
 
Join Date: Jun 2016
Posts: 6
Default Re: How To: Clutch Hydraulic system with pics

When removing the slave cylinder, the pushrod fell off and disappeared down into the clutch fork housing. So....

1. Other than the possibility of not being able to engage the clutch at an inopportune moment (because the rod had worked itself into a place that prevented clutch fork movement), is that rod likely to do any major damage if I leave it? Could it get caught in the splines of the pressure plate? could it get caught between the clutch and the flywheel?

2. What would be required to retrieve the pushrod? Would i need to pull the transmission and/or flywheel housing, or would there be some plate I could remove and gain access from the bottom?

Thanks

Last edited by marsneptune; 06-03-2016 at 05:01 PM..

REWARD EXCELLENCE!

Add to marsneptune's Reputation
Rate the quality of this post and help marsneptune reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
marsneptune is offline   Reply With Quote
Old 07-19-2016, 07:11 PM   #13
97sl5spd
Member
97sl5spd is on a distinguished road
 
Join Date: Feb 2016
Posts: 117
Default Re: How To: Clutch Hydraulic system with pics

Yeah just did mine on a 97 sl. So freaking easy it ain't funny.

REWARD EXCELLENCE!

Add to 97sl5spd's Reputation
Rate the quality of this post and help 97sl5spd reputation points. Click the reputation button near the bottom left corner of this message box. Thank you!
97sl5spd is offline   Reply With Quote
Reply



Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
Q about hydraulic clutch system MikeNW S-Series Tech 13 12-22-2011 09:11 AM
Bleeding clutch hydraulic system MikeNW S-Series Tech 2 06-03-2009 01:43 PM
Help ! Air in Hydraulic Clutch System GlennWerner S-Series General 2 12-06-2007 10:54 AM
98 SL2 clutch hydraulic system Boodah S-Series Tech 2 05-15-2007 01:40 PM
Clutch hydraulic system problems clemtwist S-Series General 4 04-03-2006 08:31 PM


All times are GMT -4. The time now is 03:00 PM.

Advanced Forum Search | Advanced Photo Search


Powered by vBulletin® Version 3.8.9
Copyright ©2000 - 2019, vBulletin Solutions, Inc.
SaturnFans.com. The Saturn Enthusiasts Site.