Manual Transmission problems of the 2004 Chevrolet Cavalier

Six problems related to manual transmission have been reported for the 2004 Chevrolet Cavalier. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Chevrolet Cavalier based on all problems reported for the 2004 Cavalier.

1 Manual Transmission problem

Failure Date: 08/17/2009

This is the second problem I've had with this. Clutch problems due to a faulty hydraulic line in a 2004 chevy Cavalier. First incident occurred may 1st when the master to slave hydraulic hose split open (was told by the ase certified repair person this should never have happened). This was a dealer only part and there are no used parts available for this. Now there are no leaks, but clutch still sticks to the floor. Driving fine, then no clutch to put car into correct gear. Had happened intermittently, but today I was in the middle of morning rush hour traffic. Almost caused several accidents when car stalled after idling really low. Shut off car while sitting at a red light-- finally after a fight with the stickshift, got into gear so I could get to a parking lot. After looking on-line for solutions and a closer repair shop, realizing this happens quite a bit to owners. I'm scared to have my 4 month old daughter in my car and would rather have her in a 1988 Mazda that the seatbelts don't click back. This is a very dangerous problem and should be addressed immediately since it happens during normal driving. If I wouldn't have had some quick thinking on my part, I probably would be in the hospital right now.

2 Manual Transmission problem

Failure Date: 11/01/2008

My 2004 chevy Cavalier was purchased may 2004 new off the lot. Since then, my clutch system has had to be replaced almost every year. It first stopped working at 36,000 miles, just 6,000 after factory warranty ran out. It then stopped working again while still under part warranty which lasts 12,000 miles. It again stopped working just a few thousand miles after that warranty ran out. And now has gone out for the fourth time in under 3,000 miles. I can always tell when the system is becoming faulty after only a few thousand miles, however due to the fact that labor is not included in any warranty, I drive it until the clutch system stops working. This has not been of any benefit to me or my car. However, I should not have to be replacing any part(s) this often, so I should not have to worry in the first place. The answer I get to what the problem is always the same, the slave cylinder o ring is "leaking like a siv" and the master cylinder has gone out. And due to these two issues, it effects the quality of my clutch fly wheel. I see no end in sight for this problem, I can not even get rebuilt parts for this problem to save myself money and as stated before, labor will never be covered under warranty. I have now paid for half the purchase price of my car in parts and labor as it was new off the lot. This lemon of a car is costing me well over $1,100 every year in repairs to the clutch system and I can not afford it any more. I have not heard yet what customer service for chevy is going to do for this but I felt that this was worth you hearing about so as to help others after me who may have the same problem and to also help me with my current problem.

3 Manual Transmission problem

Failure Date: 08/10/2008

When I was dropping my sister off at the airport, I was leaving in my Cavalier which is a manual transmission I put the car in reverse and engaged the clutch it stuck on and would not come off. I had to slam on the emergency brake and brakes to stall out the car. Once the car stalled it also came to rest against a tree, which thankfully did not cause any damage except a few scratches. On further investigation I had noticed that a hole has worn in the hydraulic rubber line from the master clutch cylinder. The hose was rubbing against a wiring harness metal brace bracket just below the clutch master cylinder. It could have caused alot of damage or personal injury or even death in the right circumstances. I had just left the halifax water front where there were about 6000 people and if the problem happened. There could have been major problems. I would like someone to look into this problem. When it happened there was no warning.

4 Manual Transmission problem

Failure Date: 02/01/2008

Clutch started feeling slushy and then failed after a few months. Clutch stays to the floor. Repair to be done, replace slave cylinder.

5 Manual Transmission problem

Failure Date: 06/20/2007

Driving home from work through city streets and suddenly was not able to disengage clutch when attempting to shift from 2nd to third. Transmission stuck in 2nd. Luckily I was only a couple miles from home. Further investigation on my part found clutch hydraulic hose had hole worn into it due to bracket location. Poor design with respect to hose configuration and bracket location. High potential for personal injury when operating.

6 Manual Transmission problem

Failure Date: 11/24/2005

While driving home from thanksgiving I was unable to shift my manual transmission, and I noticed that the clutch appeared stuck to the floor. The remainder of the way home (30 miles) if I slowed down the would stall as I could not push the clutch in. The car, a 2004 Cavalier, has a total of 42000 miles on it. Upon getting the car to the dealer I was told the master cylinder, the slave.




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