Clutch pedal intermittently loose and goes to the floor

YAHWINZ

MEMBER
2003 KIA SPECTRA
4 CYL
MANUAL
163,000 MILES

At 1st, when I pushed clutch down, it went down but I had to use my foot to pull it up and get it to engage.
Got to destination, went to leave. When pushing clutch, the tension was loose until it was halfway down, then tension was normal but it wouldn't go into gear. About a 1/2 an hour later, it worked fine.
Stopped again when I got to next destination. Went to leave and clutch went down, stayed all the way down and wouldn't go into gear.
Got towed.
When I went to check it a few days later, it was back to normal.
Thank you.

1 Reply

ASEMASTER6371

MECHANIC
52,797 POSTS

Good morning,

This sounds like either the clutch master cylinder or the slave cylinder is failing.

I would replace both units and bleed the system.

I attached the procedure below for you for the repair.

Roy

Clutch master cylinder
Removal

imageOpen In New TabZoom/Print

1. Disconnect cable.
2. Pull locktab, then remove fuse box.
3. Remove spring clip and pin from master cylinder push rod.

ImageOpen In New TabZoom/Print

4. Remove master cylinder mounting nuts.

Notice: Clutch brake fluid will damage painted surfaces so use a container or shop towels for fluid collection. If fluid gets on a painted surface, rinse immediately with clear water to prevent damage.

5. Disconnect clutch master cylinder hose.
6. Disconnect clutch hydraulic line with SST(OK130 430 019).
7. Remove clutch master cylinder.

Replacement
1. Install clutch master cylinder.
2. Tighten master cylinder mounting nuts.
3. Insert spring clip and pin into master cylinder push rod.
4. Tighten clutch hydraulic line with SST(OK130 430 019).
Tightening torque: 9.4 - 15.9 ft. Lbs. (12.7 - 21.5 Nm, 1.3 - 2.2 kg.M)

imageOpen In New TabZoom/Print

5. Connect clutch master cylinder hose.
6. Install fuse box.
7. Install cable.
8. Perform clutch hydraulic line bleeding.
9. Verify that there is no leakage.
10. Perform a road test.

Clutch release cylinder
Removal

imageOpen In New TabZoom/Print

Notice:
a) Clutch fluid will damage painted surfaces. Be sure to use a container or shop towels to collect it
b) If fluid contacts a painted surface, rinse immediately with clear water to prevent damage.

Caution: After removing the clutch line, plug the clutch line to avoid fluid leakage.

1. Raise and properly support vehicle.
2. Remove gravel shield from under engine (seven bolts).
3. Disconnect clutch line with SST(OK130 430 019).

ImageOpen In New TabZoom/Print

4. Remove two release cylinder bolts, then remove release cylinder.

Replacement
1. Install clutch release cylinder.
2. Tighten two release cylinder bolts
Tightening torque: 13.7 - 18.8 ft. Lbs. (18.6 - 25.5 Nm, 1.9 - 2.6 kg.M)
3. Tighten clutch hydraulic line flare nut with SST(OK130 430 019).
Tightening torque: 9.4 - 15.9 ft. Lbs. (12.7 - 21.5 Nm, 1.3 - 2.2 kg.M)
4. After installation, bleed the clutch system.

ImageOpen In New TabZoom/Print

5. Verify that there is no leakage.
6. Perform a road test.

Images (Click to make bigger)