CLUTCH REPLACEMENT

[old n' slow]

Reviving an old thread ?? 2004 aveo w/120,000 miles. Blew out the slave cylinder this week since the clutch fork just bent over causing the slave cylinder to explode out. Never seen that happen before on a car.

[milesvinson]

I recommend replacing the clutch release lever and fork whenever you do a clutch job on Aveos. It seems to be a common failure and will drive you nuts trying to figure it out when the lever "bends". It may appear fine like mine did, but the lever shifted or bent in the weld even though it appeared fine. This will prevent the clutch pedal from being fully pressed to the floor. Many times it will end up with you blowing out the slave cylinder. Both parts are less than $50 US dollars. Changing them while you already have the transmission out will save you from having to drop the transmission again. If your parts are fine, change them anyway. It may prevent a costly and inconvenient tow bill later. I believe the part numbers for 2004-2008 Aveos are as follows:

Part No.: 96144874 = LEVER

Part No.: 94580796 = FORK