Clutch failed in heavy traffic, cause was a rubber hydraulic hose was installed next to a sharp edge of chassis and hose eventually ruptured causing pedal to remain down and vehicle was not controllable I have reported this before and I have the part for inspection.

- Swanton Vt, VT, USA

2005 Chevrolet Cavalier - (manual transmission) when clutch pedal was pressed to change gears while driving, pedal went to floor and stayed there. Could no longer use clutch to change gears. Car stayed in gear. Problem was caused by the clutch master cylinder hydraulic line (hose) failing due to rubbing against a sharp metal electrical case. GM dealer replaced the part (#24233064), but has not modified the routing of the part. Since the new part is routed against the same sharp metal part and is rubbing against it, the failure will occur again in the future. Since the failure occurred suddenly and without warning, there failure could have caused an accident under different traffic conditions. (it is my opinion that the problem could be lessened, if the hydraulic hose routing was routed differently, or the sharp metal edge was slightly modified.) this car had 66261 miles on it, however, the part had previously been replaced at 31786 miles. Please note that this compliant is related to the following previously filed complaints: ODI id numbers 10237572, 10312149, 10163590, 10199524, 10200511, 10201764, 10231112, 10238456, 10239176,10245402, 10253573, 10260772, 10263228, 10276088, 10280611. (ODI numbers 10237572, 10312149 involved crashes.) ODI numbers 10150782, 10143646 may also be related.

- Buffalo, NY, USA

Clutch pedal fell to the floor without any warning while I was in heavy traffic almost causing a collision. The cause of the failure was that due to the poor design of the car the hydraulic clutch line was severed by a sharp piece of metal that holds an electrical housing. The line runs right a long the sharp edge of the metal and rubs against it until eventually it gets cut and all the fluid leaks out and the pedal has no pressure to engage and disengage the clutch, causing the vehicle to stay in gear and make it very hard to control.

- Poughkeepsie, NY, USA

Manual hydraulic clutch in 2005 Chevy Cavalier. Rubber hose gets worn through by metal bracket resulting in loss of clutch. I brought this to the attention of Chevrolet and they were of no assistance. I brought the vehicle in to a Chevy dealer yesterday, 10-13-08 and showed the service manager and he said that he could not fix it because there was no recall on this item. It would have to be at my cost. I drove the car home and when I attempted to start it about an hour later the hose burst causing loss of clutch and the car jumping forward about 4 feet. There needs to be a recall!

- Humble, TX, USA

My '05 Cavalier, the hydraulic clutch hose got a hole in it from rubbing on the wiring harness that is next to it. This is something that I would assume be re-routed or better put in an area where this would not happen.

- Porter, IN, USA

When pressing the clutch consumer tachometer goes to 3500 RPM and comes back down.. when in neutral at a traffic light the tachometer runs to 5500 RPM. When this occurred the consumer had to turn off the vehicle and turn it back on. The vehicle was taken to the dealer but they claimed the carpet had become entangled in the accelerator pedal. The dealer ran diagnostic test but found not problems. The consumer is still experiencing problems.

- Atlanta, GA, USA

The contact owns a 2005 Chevrolet Cavalier. The contact stated that by 3,300 miles the transmission had been repaired twice and replaced once. By the current mileage of 19,000 it has had two additional transmissions replaced. The replacements and repairs have been done at no cost to the consumer. The car has been at the dealership since February 28, 2005, when the last replacement transmission was installed because the consumer was afraid to drive the vehicle. The consumer reported this problem to the NHTSA because she did not want any one else to experience the same problems that she has encountered with this type of vehicle. The consumer wanted the dealership or manufacturer to provide a replacement vehicle at no additional charge or to provide reimbursement for the cost of the vehicle. The dealership offered for the consumer to buy another vehicle and use this one as a trade in, but the consumer refused. The consumer states that the dealership informed her that she would still have to pay for the 2005 Chevrolet Cavalier as well as for a new vehicle if she purchased one.

- Port Byron, NY, USA