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Old 09-22-2011, 06:52 PM   #1
SaturnIon2004
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Default 04' Saturn Ion Clutch Problem

Well i have a 2004 saturn ion with 66 thousand miles. three times in the last 10 days the clutch has gotten stuck feeling like the cable is hanging up. Like their wont be much pressure, then when letting the clutch out, it lets out real fast and after pumping the clutch a few times the problem goes away. I noticed on the clutch cable that goes to the transmission, right where it enters the transmission, there is a small hole with a cover over it. Is this some kind of lube point, and if it is what kind of lube would i use to maybe solve this problem. The best way to describe the problem would be the clutch gets stuck feeling and then will be extremely difficult to shift gears because its so sensitive.

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Old 09-23-2011, 12:38 PM   #2
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Default Re: 04' Saturn Ion Clutch Problem

Here is a picture of the clutch cable going into transmission with the nipple of some sorts and a rubber cap that goes over it. Is this some kind of lube point, or is it a bleed point? And again everyone once in awhile the clutch feels like it gets stuck down and i lose action in the pedal, then the clutch will release really fast. Its intermittent though, it always goes right away after a few pumps of the clutch. Does this sound like some kind of lube problem with the clutch cable itself?
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Old 09-23-2011, 11:19 PM   #3
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Default Re: 04' Saturn Ion Clutch Problem

that looks like a hydrolic line hows the cluch fluid level?

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Old 09-24-2011, 09:11 AM   #4
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Default Re: 04' Saturn Ion Clutch Problem

I had the same thing happen on my 04 QC.

Mine was only doing it on a really hot day, and only if the car was stopped and I had the clutch depressed while stopped. The pedal pressure would come back after driving for a short distance.

It seemed like the hydraulic fluid was boiling and couldn't hold pressure, and I'm pretty sure that's what was happening.

Maybe a week prior, I was trying to fix an exhaust rattle and was banging on the heat shield by the cat converter trying to figure out where the rattle was coming from. I must have pushed the heat shield up against the hydraulic line(it runs behind the tunnel heat shield). Anyway, I put the car back on the ramps and bent the shield away from the lines and I haven't lost pedal pressure again.

If the conditions when it happens sound similar, you should check your heat shield and make sure it's not causing the problem.

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Old 09-24-2011, 09:41 AM   #5
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Default Re: 04' Saturn Ion Clutch Problem

you might also need to bleed the clutch. it requires being vacuum bled.

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Old 09-24-2011, 10:32 AM   #6
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Default Re: 04' Saturn Ion Clutch Problem

Sounds like the clutch master cylinder may be letting air get by the seals and into the system. Replace the clutch master and vacuum bleed the system (brake master cylinder reservior is the clutch reservior). This should fix your problem.
Make sure first that you are not leaking brake fluid (clutch fluid) from the bell housing of the trans indicating a leaking slave cylinder.

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Old 09-24-2011, 04:44 PM   #7
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Default Re: 04' Saturn Ion Clutch Problem

Ok i checked the fluid level it was down very little bit so i just topped it off. its funny you mentioned heat shields because we were just under there replacing the cat with a walker ultra and possibly we bent the heat sheilds to bind on one of the lines, i will check that out thanks!. Also if it is the master cylinder i guess time will tell, i do have to say the symptoms are not that bad seeing how i just drove my car 200 miles yesterday and the clutch ran perfect the whole time. Thanks again for the answers!!!

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