The Geo Prizm, also called Chevrolet Prizm, has a reputation for its design and fuel efficiency. This front-wheel drive, four-door sedan has a 1.6-liter, 14-valve engine that produces 105 horsepower paired with a five-speed manual transmission. A hard pedal and grinding noises indicate that the clutch requires replacement.
Remove the Geo Prizm clutch master cylinder. Disconnect the positive battery cable and the clutch cable. Raise the vehicle with a jack, and remove the transaxle. Use a wrench to open the bolts surrounding the Geo flywheel bell housing and push the transaxle away from the engine. In a 1993 Geo Prizm, the clutch disc attaches via the pressure plate.
Remove the bolts from the pressure plate to take out the clutch disc. Check for any rips or cuts on the flywheel's friction surface. Disconnect the Geo clutch cable by removing it from the clutch pedal and the cable attachment, which operates the clutch assembly. Look for any leaks around the transaxle's input shaft. If you find any leaks, replace it. Also, replace the flywheel if the needle bearings are not lubricated. Resurface the Geo flywheel, and replace the old seal with a new one.
Attach the clutch disc to the pressure plate and tighten the bolts using the wrench. On the transaxle, connect the new needle bearings to the release fork. Mount the pressure plate to the transaxle, and tighten the bolts. Avoid using any force when moving the transaxle to a position where the input shafts fix into the clutch disc's hole.
Attach the transaxle to the engine, and tighten the bolts. Connect the clutch cable, and plug in the positive battery cable. Replace the Geo Prizm clutch master cylinder. Lower the vehicle by releasing the jack. Check whether the clutch pedal returns back to its normal position when depressed.
