For 1990-2009 cars

1. Before attempting to repair the following components for any reasons other than an obvious failure, identify the problem and probable cause:

• | The clutch

• | The transmission

• | Any related hydraulic components

2. Shifting difficulties such as the following conditions indicate a large percentage of clutch and manual transmission problems:

When any of these conditions occur, perform a careful analysis of the difficulty before removing the clutch or manual transmission for repairs.

• | A high shift effort

• | Gear clash

• | Gear grinding

• | Transmission blockout

3. Before removing the clutch hydraulic system, remove the flywheel housing cover and measure the travel of the clutch actuator pushrod in order to verify the malfunction (6-Speed Only).
4. Ensure that the clutch actuator pushrod extends a minimum of 11 mm (0.43 in) against the clutch fork with the clutch pedal pushed fully to the floor.

Do not replace the hydraulic system if the pushrod travel exceeds 11 mm (0.43 in).

Notice: Before opening the clutch master cylinder, thoroughly clean the top and sides. This is in order to prevent contamination of the system with dirt, water, or other foreign material. Before adding fluid, remove the clutch master cylinder reservoir diaphragm. Carefully replace the diaphragm, cover gasket and cover after filling the clutch master cylinder.

5. If the clutch actuator pushrod does not meet the travel requirements, check the clutch master cylinder reservoir fluid level.

• | Ensure that the clutch actuator cylinder is in place when checking the fluid level.

• | When you add fluid to or refill the system after service operations, the use of hydraulic clutch fluid GM P/N 12345347 or the equivalent is preferred over the standard DOT 3 brake fluid.

• | Do not over fill the reservoir. The upper portion of the clutch master cylinder must accept fluid that is displaced from the clutch actuator cylinder as the clutch wears.

6. If the clutch master cylinder reservoir requires any fluid, check the clutch hydraulic system components for leakage.

• | Remove the rubber boots from the clutch master cylinder.

• | Check for leakage past the pistons. A slight wetting of the surfaces is acceptable.

• | Replace the hydraulic system if excessive leakage is evident.