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Old 05-19-2019, 02:03 AM   #1
DammSaturn
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Default Impossible clutch bleed after replacing master cylinder

Hello,

I have been working on a 2003 Saturn Ion (non turbo) and we replaced a clutch pedal along with master cylinder. We spent hours upon hours trying to get the clutch bled properly and I figured I would share my method in hopes that it will help someone.

***WARNING***
BE ABSOLUTELY SURE to keep the fluid reservoir topped up throughout the entire process otherwise you will introduce more air into the system and restart the whole thing.
***WARNING***

1. I could not get the master to bench bleed properly so I chose to bleed it in the vehicle. I left the top line connected (the one that feeds from the fluid reservoir to the master), then unhook the bottom line (the one that feeds into the slave cylinder.) so anyways unhook that bottom line then attach a suitable fitting+hose into the hole where the line was and feed the line into a container of brake fluid.

2. Be sure your fluid reservoir is topped up with the cap off.

3. At this point you can have your helper begin to pump the clutch pedalrepeatedly until no more bubbles can be seen.

4. At this point with all the bubbles gone and the pedal pressed in all the way to the floor, you can put the cap on the fluid resevoir(to prevent fluid from running out) and go ahead and remove your hose from the bottom of the master then click the clutch line/hydraulic assembly back in and re attach the clip.

It seemed weird to me the do this with the pedal pressed all the way in, you would think it would be the other way around, but this is the only way I could get it to work.

5. Now you can take the cap back off the fluid reservoir. Get your vacuum pump set up and attach to the bleeder nipple by the bell housing. Pull down about 15” of vacuum.

6. Pull the clip out that holds in the fluid line, then pull out the fluid line just about 1/4” or until you can see the fluid start to flow. Don’t pull the line out too much or you will introduce more air into the system.

7. Pump up your vacuum to about 20” or so, and have your helper push the pedal in all the way and hold it, you should see some air bubbles coming out now.

8. Continue to have your helper pump the pedal 2-3 times then hold the pedal down as air bubbles start to come out. You may have to vacuum all the way to 25-30” if necessary to get all the air out.

9. Once no more air is coming out, with the clutch pedal pressed in all the way, put the fluid line back in all the way, insert the clip, and have your helper let the pedal out. Once the bleeder is closed and clip inserted you can pump the pedal a few times to refill the hydraulic cylinder and get an idea for where you are at with pedal feel.

10. Let the car sit 5-10 min to allow any aerated fluid to settle.

11. Repeat steps 6-10 as many times necessary til you’ve got good pedal feel.

Last edited by DammSaturn; 05-19-2019 at 02:14 AM..

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Old 05-19-2019, 12:18 PM   #2
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Default Re: Impossible clutch bleed after replacing master cylinder

Here's a copy from the service manual on how to bleed the clutch hydraulic system.
Attached Files
File Type: pdf Service Information.pdf (67.4 KB, 13 views)

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Old 05-19-2019, 01:09 PM   #3
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Default Re: Impossible clutch bleed after replacing master cylinder

http://www.saturnfans.com/forums/sho...d.php?t=184345

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Old 05-20-2019, 03:45 AM   #4
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Default Re: Impossible clutch bleed after replacing master cylinder

Quote:
Originally Posted by fdryer View Post
Here's a copy from the service manual on how to bleed the clutch hydraulic system.
I think maybe you misunderstood my post. We managed to get it bled, I was just posting my method Incase anyone was interested

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Old 05-20-2019, 11:48 AM   #5
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Default Re: Impossible clutch bleed after replacing master cylinder

It's always good to have service manual procedures. If a short cut can make it easier with your method then adapting from recommended procedures is even better. I'd call that a win-win solution.

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Old 05-20-2019, 09:20 PM   #6
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Default Re: Impossible clutch bleed after replacing master cylinder

These clutch are SUPER EASY to bleed, you just need to know exactly how.

Follow this guys, that is how I learned. Did it multiple times. Just by gravity and toping it up. Clear countainer, Clear rubber tub, Brake Bleeder fitting, Screw Driver.

https://www.youtube.com/watch?v=wXbOrxWv65Q

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Saturn Ion 3 Quad Coupe 3 with Sports Appearance package with Aura Pro Bass Shakers under the front seats, Kenwood Excelon Mono Amplifier and Infinity Kappa Perfect and I'm In Heaven!!!!

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Old 06-29-2019, 05:36 PM   #7
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Default Re: Impossible clutch bleed after replacing master cylinder

Long time lurker here who has found lots of help.

My daughter's 2003 Ion Quad Coupe with a 5-speed suffered from what appeared to be a clutch MC failure. After a couple of hours in a parking lot with a MityVac I was still unable to generate any pedal pressure. I'm going to tow it to the house where I have tools and shop air for a different bleeder.

When trying to remove the MC I broke this off of it at the connector. I can find no reference to it anywhere. What is it? It goes between the MC and the line to the slave cylinder and clutch MC. I just plugged the line into the MC directly, no leaks.

So what is this?

Thanks,
Nick
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File Type: jpg clutch.jpg (83.3 KB, 8 views)

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Old 07-23-2019, 05:14 PM   #8
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Default Re: Impossible clutch bleed after replacing master cylinder

I've answered my own question, that's a damper in the fluid line from the master cylinder to the slave.

If you need one it is available from GM only as part of the line.

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