1996 Saturn SL2 hard shifting

Tiny
MEBURKE
  • MEMBER
  • 1996 SATURN SL2
  • 4 CYL
  • 2WD
  • MANUAL
  • 130,000 MILES
Okay have done this. Replaced cables, replaced clutch

shifts smooth for about 6-9 miles, clutch pedal not quite to the floor when shifting, typical NC Piedmont driving (hills, curves, stop signs and/or turns every couple of miles) at about 9 miles of travel shifting starts to get difficult. Meaning it doesn't slide in quite as easy, kinda bumps. At about 15 miles sometimes it will not go in gear, if I have the the shifter in position to go in gear it will not slip in unless I push the pedal all the way to the floor. At about 25 miles the clutch pedal to floor needs to be done about 75% of time. Rpms don't seem to be important as at times when at a stop the pedal needs to be floored. Double clutching seems to work though isn't a guarantee. Checked the travel of the throw-out bearing lever both hot and cold, close to the same.
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Sunday, August 15th, 2010 AT 7:20 PM

10 Replies

Tiny
SATURNTECH9
  • EXPERT
When you change gear's you don't push the clutch pedal all the way to the floor?Also is your clutch pedal hard all the way to the floor or does it drop down some before it get's hard?
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Monday, August 16th, 2010 AT 1:27 AM
Tiny
MEBURKE
  • MEMBER
Clutch feels fine entire travel, when cool the shifting is just short of floor, when warm need to go to the floor solid.
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Monday, August 16th, 2010 AT 5:55 AM
Tiny
SATURNTECH9
  • EXPERT
So if you push the clutch all the way to the floor when it's hot does it shift good?
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Monday, August 16th, 2010 AT 1:22 PM
Tiny
MEBURKE
  • MEMBER
Yes, but it I have to have it hard to the floor. Usually use the toe of my foot to make sure. If I flat foot it, my foot hits where the floor curves up before I can get the pedal down tight.I mean, it is bottomed out, can't go no further to the floor.
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Monday, August 16th, 2010 AT 2:43 PM
Tiny
MEBURKE
  • MEMBER
This was the original issue. Hard shifting of the gears.
It is my daughters and she had the cables replaced, on a trip it started the hard shifting again, particularly getting in reverse, till she was stuck by the side of the road, the cables were changed again, in what I might think was quick fix by the folks to where it was towed, I replaced the clutch as it seemed the likely suspect, given the way it was behaving. And while this seemed to make things better, I still have the same underlying problem hard shifting.I don't suppose the clutch cylinders might be the problem, (though there is no leakage) as the transmission route is not fiscally practical.
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Monday, August 16th, 2010 AT 3:01 PM
Tiny
SATURNTECH9
  • EXPERT
When you replaced the clutch did you replace the pressure plate clutch disc throw out bearing and flywheel or have it resurfaced?Also if you have the clutch slave cylinder inserted correctly and your clutch pedal is hard all the way down I would say that wouldn't be an issue.
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Tuesday, August 17th, 2010 AT 2:44 PM
Tiny
MEBURKE
  • MEMBER
Replaced all clutch parts, check the flywheel, seemed okay.
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Wednesday, August 18th, 2010 AT 8:00 AM
Tiny
SATURNTECH9
  • EXPERT
You should have replaced the flywheel or had it resurfaced they make clutch kit's that come with a flywheel for a reasonable amount. That's not causing your problem though if the cable's clutch and clutch master and slave are good only thing left is the transmission. But when you have trouble shifting when it get's hot it's usually the clutch. When you have trouble just shifting into some gear's it's the transmission. All the gear's it's the clutch.
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Wednesday, August 18th, 2010 AT 1:52 PM
Tiny
MEBURKE
  • MEMBER
Gotcha. Probably should have done the flywheel, but the clutch disk looked fairly good, and I didn't see any notable signs of wear on the flywheel. The fingers on the pressure plate were somewhat beat up, and the throwout bearing was ready to be replaced. From what you have said I believe the transmission is the issue.I greatly appreciate your assistance.

Thanks
meburke
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Wednesday, August 18th, 2010 AT 2:25 PM
Tiny
SATURNTECH9
  • EXPERT
Your welcome for help that's what were here. Also thanks for the donation.
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Wednesday, August 18th, 2010 AT 7:04 PM

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