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George B
New User
May 14, 2007, 4:22 PM
Post #1 of 5
(2035 views)
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2003 Sunfire 5th gear
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My daughter's 2003 Sunfire, 124000 km, started having a slight grind going into 5th gear. Quiet going into other gears, and runs fine in all gears. I do think the clutch engages too quickly but have not driven these before last week. Is this a clutch problem or selectors.
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Tom Greenleaf
Ultimate Carjunky
/ Moderator
May 15, 2007, 6:58 AM
Post #2 of 5
(2029 views)
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Re: 2003 Sunfire 5th gear
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The clutch engaging too quickly is a clue. If when the clutch pedal is to the floor is not enough to full disengage clutch then it turns and only syncronizers can make the adjustment for a no grind shift. They can handle a bit but there is a limit. The problem would be worse downshifting especially into 1st. If just a single syncro it could be any gear. Reverse is not generally syncronized TMK and if you hold clutch to floor, shifter in neutral for a several seconds and then shift very slowly into reverse it may give you a zip/grind which it shouldn't. That is because the clutch is not fully disengaged. That can be it's freeplay adjustment or a linkage problem or a clutch that isn't true from corrosion or was replaced and left hanging on center splines which distorted the disc out of range for full disengagement. That problem usually causes clutch chatter (shaking when engaging) and can only be really corrected by replacing the disc.
Take time to diagnose this exactly as possible as to not be replacing parts that don't solve the problem. If a bad syncro it had best be cracked or just a new one might not fix it. The main shaft could be worn and I don't think that can be fixed but would have to be replaced.
You may want to just put up with this problem if not too bad as it would require a lot of detailed work to get at the area.
Again---- take your time with diagnosis ---- it's too much work to be wrong,
T
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George B
New User
May 15, 2007, 8:36 AM
Post #3 of 5
(2026 views)
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Re: 2003 Sunfire 5th gear
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Tom, Thanks for your Hints.
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George B
New User
May 16, 2007, 1:40 PM
Post #4 of 5
(2016 views)
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Re: 2003 Sunfire 5th gear
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The clutch seems fine, I was unfamiliar first drive. There is free play, 2-3 inches, before engaging quickly then very little play when released fully. The car can start with shifter in gear. Except for 5th there is no grinding up, down or reverse. When driving if you pause in neutral, then pump clutch once then shift to 5th there is no grinding. A good temporary solution. There isn't any chattering or bearing noise going into any gear. Any ideas????
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Tom Greenleaf
Ultimate Carjunky
/ Moderator
May 16, 2007, 2:33 PM
Post #5 of 5
(2015 views)
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Re: 2003 Sunfire 5th gear
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Does this car have the hydraulic clutch linkage? Just as a test try just sitting still in neutral -- foot off clutch rev engine up a bit to perhaps 2,000 RPM and then just go and push clutch and into 5th gear. I'm not sure about this but I bet it will grind and maybe there's a linkage problem that could solve this,
T
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