Hello all, new to the forum but I’m having some issues with my ion. I have a 2.4 with a manual 5 speed. The clutch master cylinder rod broke right behind where the ball connects to the pedal. I cannot find any master cylinders that fit as all of the rods are too short and the ball connections are too small. Has anybody ran into this before? I purchased a new clutch pedal assembly as well but it also will not work. Any advice or insight would be greatly appreciated.
Senior Member
Why do you think the rod is too short? Have you compared the rod on the new unit to the parts of the old unit. As far as I know all Ions use the same master cylinder. The ball of the master cylinder rod fits into a bushing in the pedal. If the bushing is missing, the rod will go further into the pedal, or possibly through the plastic (if badly worn) in the pedal where the bushing is supposed to fit. There was a thread a couple of years ago about locating these replacement bushings. They are very hard to find, but it seems there was a retailer that had some for around $30. I don't have the details.
Senior Member
Regarding the clutch master cylinder rod bushing, the Ion forum sticky dated Dec 28, 2024 addresses this issue. Post #10 says Amazon sells a GM clutch pedal that includes the bushing, but I don't think Amazon carries the GM part any more. Post #17 has a listing for a seller who will oblige you for $40.
It’s a 2007 ion with the 2.4 and the F23 5 speed manual. When I looked it up I have found that part numbers Dorman: CM64011 and Duralast: CC650110 are what it originally was designed for. I replaced the clutch pedal assembly and master cylinder and the rod is too short to reach the pedal and the ball is too small for the pedal. I can’t find any at junk yards around me.
my next thought is to buy the pedal from a 2.2/2.0 and try that.
my next thought is to buy the pedal from a 2.2/2.0 and try that.
Quote:
Originally Posted by oldmarine
Why do you think the rod is too short? Have you compared the rod on the new unit to the parts of the old unit. As far as I know all Ions use the same master cylinder. The ball of the master cylinder rod fits into a bushing in the pedal. If the bushing is missing, the rod will go further into the pedal, or possibly through the plastic (if badly worn) in the pedal where the bushing is supposed to fit. There was a thread a couple of years ago about locating these replacement bushings. They are very hard to find, but it seems there was a retailer that had some for around $30. I don't have the details.
the pedal assembly comes with the bushing. It’s still too small and the ball wont reach the pedal.
Senior Member
I don't know where you're doing your part searches. AutoZone (Duralast) shows the master cylinder for a 2007 Ion 2.4L 5 speed to be CM2342, and RockAuto shows the Dorman unit for the same car to be CM640099 (same part for all 2003-2007 Ions).
Quote:
Originally Posted by oldmarine
I don't know where you're doing your part searches. AutoZone (Duralast) shows the master cylinder for a 2007 Ion 2.4L 5 speed to be CM2342, and RockAuto shows the Dorman unit for the same car to be CM640099 (same part for all 2003-2007 Ions).
I took the Autozone part number from the guy at that store. From what I can see the one you have is the one that replaced the one I put. I have the CM640099 and it’s too short.
Senior Member
I don't know what else to offer regarding your situation. I can only find one part number (per manufacturer) for any year Ion.(including Red Line).
You don't have damage/distortion in the sheet metal of the firewall where the master cylinder is mounted, do you? (See https://www.saturnforum.com/forum/sa...irewall-13785/)
You don't have damage/distortion in the sheet metal of the firewall where the master cylinder is mounted, do you? (See https://www.saturnforum.com/forum/sa...irewall-13785/)
Quote:
You don't have damage/distortion in the sheet metal of the firewall where the master cylinder is mounted, do you? (See https://www.saturnforum.com/forum/sa...irewall-13785/)
I don’t see any. I’ll have to check and see what’s what then. Thank you guys Originally Posted by oldmarine
I don't know what else to offer regarding your situation. I can only find one part number (per manufacturer) for any year Ion.(including Red Line).You don't have damage/distortion in the sheet metal of the firewall where the master cylinder is mounted, do you? (See https://www.saturnforum.com/forum/sa...irewall-13785/)