CLUTCH
SECTION
CL
CONTENTS
PRECAUTIONS 2
Precautions 2
PREPARATION 3
Special Service Tools 3
Commercial Service Tools 3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING 4
NVH Troubleshooting Chart 4
CLUTCH
4
CLUTCH SYSTEM - HYDRAULIC TYPE 5
Components 5
Inspection and Adjustment 6
ADJUSTING CLUTCH PEDAL
6
AIR BLEEDING PROCEDURE
7
CLUTCH MASTER CYLINDER 8
Components 8
Disassembly and Assembly 8
Inspection 8
OPERATING CYLINDER 9
Components 9
Inspection 9
CLUTCH RELEASE MECHANISM 10
Components 10
Removal and Installation 10
Inspection 11
Lubrication 11
Waterproof - for 4WD Model 11
CLUTCH DISC, CLUTCH COVER AND
FLYWHEEL 12
Components 12
Inspection and Adjustment 12
CLUTCH DISC
12
CLUTCH COVER AND FLYWHEEL
13
FLYWHEEL INSPECTION
13
Installation 13
SERVICE DATA AND SPECIFICATIONS (SDS) 14
Clutch Control System 14
Clutch Master Cylinder (with clutch damper) 14
Clutch Operating Cylinder 14
Clutch Disc 14
Clutch Cover 14
Clutch Pedal 14
GI
MA
EM
LC
EC
FE
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
SBR686C
Precautions
NGCL0001
¼ Recommended fluid is brake fluid “DOT 3”.
¼ Never reuse drained brake fluid.
¼ Be careful not to splash brake fluid on painted areas.
¼ When removing and installing clutch piping, use Tool.
¼ Use new brake fluid to clean or wash all parts of master
cylinder, operating cylinder, and clutch damper.
¼ Never use mineral oils such as gasoline or kerosene. It will
ruin the rubber parts of the hydraulic system.
WARNING:
After cleaning the clutch disc, wipe it with a dust collector. Do
not use compressed air.
PRECAUTIONS
Precautions
CL-2
Special Service Tools
NGCL0002
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name
Description
ST20630000
(J26366)
Clutch aligning bar
NT405
Installing clutch cover and clutch disc
a: 15.9 mm (0.626 in) dia.
b: 22.8 mm (0.898 in) dia.
c: 55 mm (2.17 in)
ST20050240
(—)
Diaphragm spring adjust-
ing wrench
NT404
Adjusting unevenness of diaphragm spring of
clutch cover
a: 150 mm (5.91 in)
b: 25 mm (0.98 in)
Commercial Service Tools
NGCL0003
Tool name Description
1 Flare nut crowfoot
2 Torque wrench
NT360
Removing and installing clutch piping
a: 10 mm (0.39 in)
Bearing puller
NT077
Removing release bearing
Bearing drift
NT474
Installing release bearing
a: 52 mm (2.05 in) dia.
b: 45 mm (1.77 in) dia.
GI
MA
EM
LC
EC
FE
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PREPARATION
Special Service Tools
CL-3
NGCL0027
NVH Troubleshooting Chart
NGCL0027S01
Use the chart below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, repair or replace these parts.
CLUTCH
NGCL0027S0101
Reference page
CL-6
CL-7
CL-8
CL-9
EM-41
,
EM-100
CL-10
CL-12
CL-12
CL-12
CL-12
CL-12
CL-12
CL-12
CL-12
CL-13
CL-13
CL-13
CL-13
SUSPECTED PARTS
(Possible cause)
CLUTCH PEDAL (Free play out of adjustment)
CLUTCH LINE (Air in line)
MASTER CYLINDER PISTON CUP (Damaged)
OPERATING CYLINDER PISTON CUP (Damaged)
ENGINE MOUNTING (Loose)
RELEASE BEARING (Worn, dirty or damaged)
CLUTCH DISC (Out of true)
CLUTCH DISC (Runout is excessive)
CLUTCH DISC (Lining broken)
CLUTCH DISC (Dirty or burned)
CLUTCH DISC (Oily)
CLUTCH DISC (Worn out)
CLUTCH DISC (Hardened)
CLUTCH DISC (Lack of spline grease)
DIAPHRAGM SPRING (Damaged)
DIAPHRAGM SPRING (Out of tip alignment)
PRESSURE PLATE (Distortion)
FLYWHEEL (Distortion)
Symptom
Clutch grabs/chatters 1 2 2 2 2 2
Clutch pedal spongy 1 2 2
Clutch noisy 1
Clutch slips 1 2 2 3 4 5
Clutch does not disengage 1234 55555 5667
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
CL-4
Components
NGCL0004
ACL106
1. Clutch pedal bracket
2. Clutch interlock switch
3. Clutch master cylinder
4. Fulcrum pin
5. Bushing
6. Clevis pin
7. Clutch pedal
8. Lock nut
9. ASCD cancel switch
10. Pedal stopper
11. Snap pin
12. Assist spring
13. Clutch disc
14. Clutch cover
15. Release bearing
16. Release bearing sleeve
17. Withdrawal lever
18. Dust boot
19. Operating cylinder
20. Air bleeder
21. Clutch damper
22. Flare nut
23. Bushing
GI
MA
EM
LC
EC
FE
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
CLUTCH SYSTEM — HYDRAULIC TYPE
Components
CL-5
ACL107
Inspection and Adjustment
NGCL0005
ADJUSTING CLUTCH PEDAL
NGCL0005S01
1. Adjust pedal height with pedal stopper or ASCD cancel switch.
Pedal height “H”:
KA24DE: 221 – 231 mm (8.70 – 9.09 in)
VG33E: 227 – 237 mm (8.94 – 9.33 in)
ACL104
2. Adjust pedal free play with master cylinder push rod. Then
tighten lock nut.
Pedal free play (measured at pedal pad) “A”:
9 - 16 mm (0.35 - 0.63 in)
Pedal free play means the following total measured at position
of pedal pad:
¼ Play due to clevis pin, clevis pin hole in clutch pedal and
master cylinder.
3. Make sure that clevis pin can rotate smoothly. If not, readjust
pedal free play with master cylinder push rod.
CLUTCH SYSTEM — HYDRAULIC TYPE
Inspection and Adjustment
CL-6
ACL103
— Models with Clutch Interlock System —
NGCL0005S0101
1. Adjust clearance “C” shown in the figure while fully depressing
clutch pedal.
Clearance C:
0.1 - 1.0 mm (0.004 - 0.039 in)
SCL203-A
AIR BLEEDING PROCEDURE
NGCL0005S02
Bleed air according to the following procedure.
Bleed air from operating cylinder.
1) Fill the master cylinder reservoir tank with new brake fluid.
2) Connect a transparent vinyl hose to the air bleeder.
3) Slowly depress the clutch pedal to its full stroke length and
release it completely. Repeat this operation several times at 2
to 3 second intervals.
4) Open the air bleeder with the clutch pedal fully depressed.
5) Close the air bleeder.
6) Release the clutch pedal and wait at least 5 seconds.
7) Repeat steps 3 through 6 above until air bubbles no longer
appear in the brake fluid
GI
MA
EM
LC
EC
FE
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
CLUTCH SYSTEM — HYDRAULIC TYPE
Inspection and Adjustment (Cont’d)
CL-7
Components
NGCL0006
ACL108
Disassembly and Assembly
NGCL0007
¼ Use a screwdriver to remove stopper ring while pushing push
rod into cylinder.
¼ When installing stopper ring, tap in lightly while pushing push
rod into cylinder.
Inspection
NGCL0008
Check the following items, and replace if necessary.
¼ Rubbing surface of cylinder and piston, for uneven wear, rust,
or damage
¼ Piston with piston cup, for wear or damage
¼ Return spring, for wear or damage
¼ Dust cover, for cracks, deformation, or damage
¼ Reservoir, for deformation or damage
CLUTCH MASTER CYLINDER
Components
CL-8
Components
NGCL0009
ACL109
Inspection
NGCL0010
Check the following items, and replace if necessary.
¼ Rubbing surface of cylinder and piston, for uneven wear, rust,
or damage
¼ Piston with piston cup, for wear or damage
¼ Piston spring, for wear or damage
¼ Dust cover, for cracks, deformation, or damage
GI
MA
EM
LC
EC
FE
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
OPERATING CYLINDER
Components
CL-9
Components
NGCL0013
ACL110
CL145
Removal and Installation
NGCL0014
¼ Remove release bearing.
SCL705
¼ Install release bearing with suitable drift.
SCL217
¼ Install retainer spring and holder spring.
CLUTCH RELEASE MECHANISM
Components
CL-10
Inspection
NGCL0015
Check the following items, and replace if necessary.
¼ Release bearing, to see that it rolls freely and is free from
noise, cracks, pitting, or wear.
¼ Release sleeve and withdrawal lever rubbing surface, for wear,
rust, or damage
ACL105
Lubrication
NGCL0016
¼ Apply recommended grease to contact surface and rubbing
surface.
¼ Too much lubricant might damage clutch disc facing dam-
age.
ACL094
Waterproof — for 4WD Model
NGCL0017
¼ Apply recommended sealant to contact surface of dust cover
to transmission case and withdrawal lever and then install dust
cover clip.
Recommended sealant: Nissan genuine part (KP115-
00100), Three Bond TB1212, Loctite Part Number
51813, or equivalent
GI
MA
EM
LC
EC
FE
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
CLUTCH RELEASE MECHANISM
Inspection
CL-11
Components
NGCL0018
ACL100
ACL063
Inspection and Adjustment
NGCL0019
CLUTCH DISC
NGCL0019S01
Check the following items, and replace if necessary.
¼ Clutch disc, for burns, discoloration, oil, or grease leakage
¼ Clutch disc, for wear of facing
Wear limit of facing surface to rivet head:
0.3 mm (0.012 in)
ACL064
¼ Clutch disc, for backlash of spline and runout of facing
Maximum backlash of spline (at outer edge of disc):
1.0 mm (0.039 in)
Runout limit:
1.0 mm (0.039 in)
Distance of runout check point (from hub center):
Model 240: 115 mm (4.53 in)
Model 250: 120 mm (4.72 in)
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Components
CL-12
SCL466
CLUTCH COVER AND FLYWHEEL
NGCL0019S02
¼ Check clutch cover, installed on vehicle, for uneven diaphragm
spring toe height.
Uneven limit:
KA24DE: 0.7 mm (0.028 in)
VG33E: 0.5 mm (0.0020 in)
¼ If out of limit, adjust the height with Tool.
AEM100
FLYWHEEL INSPECTION
NGCL0019S03
CAUTION:
Do not allow any magnetic materials to contact the ring gear
teeth.
¼ Inspect contact surface of flywheel for slight burns or discol-
oration. Clean flywheel with emery paper.
¼ Check flywheel runout.
Maximum allowable runout:
Refer to EM-52 (KA24DE engine) or EM-110 (VG33E
engine), “Inspection”, “CYLINDER BLOCK”.
ACL079
Installation
NGCL0020
¼ Apply recommended grease to contact surface of splines.
¼ Too much lubricant may damage clutch disc facing.
¼ Insert Tool into clutch disc hub when installing clutch cover and
disc.
¼ Be careful not to allow grease to contaminate clutch facing.
¼ Tighten bolts in numerical order, in two steps.
First step:
: 10 - 20 N·m (1.0 - 2.0 kg-m,7-14ft-lb)
Final step:
: 22 - 29 N·m (2.2 - 3.0 kg-m, 16 - 22 ft-lb)
GI
MA
EM
LC
EC
FE
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Inspection and Adjustment (Cont’d)
CL-13
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