PI0421C

Bulletin No.: PI0421C
Date: Nov-2012
Subject:
Fluid Leak after Clutch Actuator Replacement
Models:
2011-2013 Chevrolet Cruze
2012-2013 Chevrolet Sonic
Equipped with Manual Transmission
This PI is being revised to add the Chevrolet Sonic and the 2013 model year. Please discard PI0421B.
Condition/Concern
Some customers may comment on a fluid leak from under the front of the vehicle, the clutch pedal is hard to push, returns slow, does not return all the way to
the top or does not return at all.
Technicians may also notice the clutch pedal is hard to bleed or clutch slave cylinder seal fails after 3-4 clutch pedal pumps and a fluid leak is observed from
the clutch actuator cylinder pipe elbow after the clutch actuator cylinder replacement. The condition may be present as soon as the repair is completed or may
surface within 1,600 km (1,000 mi) of repair. The vehicle may also have a repeat clutch performance concern such as slip or high shift effort and clash.
Further inspection may reveal that the leak is brake fluid coming from the clutch actuator cylinder pipe elbow.
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After replacement of the clutch actuator cylinder, the seal from the clutch actuator cylinder pipe may be retained in the pipe elbow. The new clutch actuator
cylinder has a new seal attached to the pipe and if the old seal is not removed, it can cause a poor seal allowing fluid to leak. It can also cause a blockage in the
pipe restricting flow into or out of the clutch actuator cylinder. If the seal is in the right position, fluid will enter the clutch actuator cylinder but does not exhaust
and after 3-4 clutch cycles, the cylinder over strokes and the seal fails. The seal can also block the line where the clutch cylinder will not stroke and the pedal
will feel hard.
Recommendation/Instructions
Remove the old seal from the clutch actuator cylinder elbow pipe following the procedure below.
1.
Raise the vehicle.
2.
Disconnect the clutch actuator cylinder elbow pipe and remove the old seal (1).
3.
Connect the clutch actuator cylinder elbow pipe. Make sure there is only one seal in place.
4.
Lower the vehicle.
Warranty Information
For vehicles repaired under warranty, use:
Labor
Operation
Description
Labor Time
K9709*
Remove Clutch Actuator
Cylinder Elbow Seal
0.3 hr
*This is a unique labor operation for bulletin use only. It will not be
published in the Labor Time Guide.
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may
occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools,
safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that
your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information.
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