2008 HHR SS Manual
Clutch: Stock
Mileage: 152K
Symptom: Sometimes … the clutch pedal stick halfway down and I have to lift it with my foot.
Replaced: 1. The clutch return spring and 3 blue bushings. 2. Clutch master cylinder. Greased everything, of course. Fluid has been changed a few times.

The problem still exists. It feels like it is just the pedal hanging up - there is no clutch slipping, no sponginess, etc. There is some "squeaking" from the bellhousing, presumably from the slave or the spines. I've read everything I can find here, and at the Cobalt sites (not sure this is even the same componentry).

I guess what I am wondering is if the main clutch pedal fulcrum can also hang up. I'm thinking it can only be that or the slave cylinder hanging up internally or on the splines - but in that case, I expect the clutch to still be low/spongy even after I lift the clutch pedal with my foot?

Any help is appreciated.

-P

 

Hi Pat, to the forum!!

I had a similar problem, check out this thread, it will give you something to look for.

https://www.chevyhhr.net/forums/how-...dal-arm-55769/

 

Hi, and thanks for the quick reply! I never broke the spring, but that center "horseshoe" bushing was cracked. I replaced it all - the 3 bushings and the spring. But it didn't fix the problem. UNFORTUNATELY, when I was replacing the Master Cylinder, I didn't study the other joint (the main fulcrum above where all the blue bushing stuff is going on) of the clutch pedal for binding.

I'm a bit uncertain as to whether it is slave/splines or just the pedal joints … but the C5 Corvette guys say this happens on those cars, and it is all about the slave cylinder - they say GM has a fluid that helps - and some of the aftermarket tuner shops ALSO have supplemental return springs. Obviously I don't want to go into the bellhousing if I don't have to! It is just a but harder finding shops and people that have a lot of experience with the HHR SS.

 

There have been reports of bulkhead fatigue where the bolts go through.

Here is the drawing from the shop manual:

 

What I was getting at is to check for a groove worn into the clutch pedal arm, that can cause binding.

 

Thanks, Don. Is the fatigue related to the things I read about the firewall reinforcement around the "twist and lock" attachment for the clutch master, and whether it has the blue o-ring or black o-ring? When I replaced the master, things LOOKED fine in that area - and it didn't LOOK like a car that had a retrofit reinforcement, but I could never find a picture of what the reinforcement kit looked like. My firewall is all original paint, nothing looked like an add on reinforcement, but I was only looking from the engine bay side.

The dealer tried to help me figure out which master cylinder to get based on the VIN, since the kits seemed to indicate that they would come with a firewall reinforcement plate (or not).

Kicking myself for not looking real closely at the pedal when I had the master cylinder disconnected. But it doesn't always do it, either!

 

Right. Mine was worn a little compared to yours, and I didn't refurbish it like you did - but maybe what you are trying to tell me is that the blue horseshoe might be "squeezing" the spring even if it isn't broken? I will certainly look at that first! Thanks again!

 

I have never actually seen the clutch on an HHR.

From a little GoOgling, that "squeaking" is probably the throw out bearing which seems to be part of the slave cylinder.

Here is a thread about the firewall problem. https://www.chevyhhr.net/forums/problems-service-repairs-42/i-see-how-fourm-58700/
http://oemcats.com/oem-parts/20842466.html

 

Mine did this when I had air in the brake system. You may have already done it, but make sure your brake system is a-ok. If you are doing it at home, be sure to exercise the ABS. Air can be anywhere.

 

I thought the hydraulics were separated on the HHR. But, could be air.