TRANSMISSION/TRANSAXLE

CL
A

B
SECTION
CLUTCH CL

E
CONTENTS
SERVICE INFORMATION ............................ 2 OPERATING CYLINDER .................................. 10 F
Component ..............................................................10
PRECAUTIONS ................................................... 2 Removal and Installation .........................................10
Precaution for Supplemental Restraint System Disassembly and Assembly .....................................10 G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Inspection ................................................................11
SIONER" ................................................................... 2
Precaution ................................................................. 2 CLUTCH PIPING ............................................... 12
Component ..............................................................12 H
PREPARATION ................................................... 3 Removal and Installation .........................................12
Special Service Tool ................................................. 3
Commercial Service Tool .......................................... 3 CLUTCH RELEASE MECHANISM ................... 13 I
Component ..............................................................13
NOISE, VIBRATION AND HARSHNESS Removal and Installation .........................................13
(NVH) TROUBLESHOOTING ............................. 4 Inspection ................................................................14
NVH Troubleshooting Chart ...................................... 4 J
CLUTCH DISC, CLUTCH COVER AND FLY-
INSPECTION AND ADJUSTMENT ..................... 5 WHEEL .............................................................. 16
Inspection and Adjustment ........................................ 5 Component ..............................................................16 K
Removal and Installation .........................................16
CLUTCH PEDAL ................................................. 7 Inspection and Adjustment ......................................17
Component ................................................................ 7
Removal and Installation ........................................... 7 L
SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................. 19
CLUTCH MASTER CYLINDER ........................... 8
Clutch Control System .............................................19
Component ................................................................ 8 M
Clutch Master Cylinder (with clutch damper) ...........19
Removal and Installation ........................................... 8
Clutch Operating Cylinder .......................................19
Disassembly and Assembly ...................................... 8
Clutch Disc ..............................................................19
Inspection .................................................................. 9
Clutch Cover ............................................................19 N

Revision: April 2013 CL-1 2013 D22 LCV

 PRECAUTIONS
< SERVICE INFORMATION >
SERVICE INFORMATION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000008944595

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SRS section.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni-
tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a
hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Precaution INFOID:0000000008944596

WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not use compressed air.
CAUTION:
• Clutch fluid use refer to MA-9, "Fluids and Lubricants".
• Do not reuse drained clutch fluid.
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
• Do not use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic
system.

Revision: April 2013 CL-2 2013 D22 LCV

 PREPARATION
< SERVICE INFORMATION >
PREPARATION
A
Special Service Tool INFOID:0000000008944597

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. B
Tool number Description
(Kent-Moore No.)
Tool name
CL
ST20600000 Installing clutch cover and clutch disc
(J-26366) a: 16 mm (0.630 in) dia.
Clutch aligning bar b: 22.8 mm (0.898 in) dia.
c: 55 mm (2.17 in) D

E
NT405

ST20050240 Adjusting unevenness of diaphragm spring of

( — ) clutch cover
Diaphragm spring adjusting wrench F

ZZA0508D

Commercial Service Tool INFOID:0000000008944598

H

Tool name Description I

1. Flare nut crowfoot Removing and installing clutch piping
2. Torque wrench a: 10 mm (0.39 in)
J

K
NT360

Bearing puller Removing release bearing

L

NT077

Bearing drift Installing release bearing N

a: 52 mm (2.05 in) dia.
b: 45 mm (1.77 in) dia.
O

NT474
P

Revision: April 2013 CL-3 2013 D22 LCV

 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SERVICE INFORMATION >
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart INFOID:0000000008944599

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.

EM-51

CL-14

CL-17

CL-17

CL-17

CL-17
CL-11
CL-5

CL-5

CL-9
Reference page

OPERATING CYLINDER PISTON CUP (Damaged)

MASTER CYLINDER PISTON CUP (Damaged)

RELEASE BEARING (Worn, dirty or damaged)

CLUTCH PEDAL (Inspection and Adjustment)

DIAPHRAGM SPRING (Out of tip alignment)

CLUTCH DISC (Lack of spline grease)
CLUTCH DISC (Runout is excessive)

DIAPHRAGM SPRING (Damaged)

CLUTCH DISC (Dirty or burned)

PRESSURE PLATE (Distortion)

CLUTCH DISC (Lining broken)
ENGINE MOUNTING (Loose)
SUSPECTED PARTS

CLUTCH DISC (Out of true)

CLUTCH DISC (Hardened)

CLUTCH DISC (Worn out)
CLUTCH LINE (Air in line)

(Possible cause)

FLYWHEEL (Distortion)
CLUTCH DISC (Oily)
Clutch grabs/chatters 1 2 2 2 2 2
Clutch pedal spongy 1 2 2
Clutch noisy 1
Symptom
Clutch slips 1 2 2 3 4 5
Clutch does not disen-
1 2 3 4 5 5 5 5 5 5 6 6 7
gage

Revision: April 2013 CL-4 2013 D22 LCV

 INSPECTION AND ADJUSTMENT
< SERVICE INFORMATION >
INSPECTION AND ADJUSTMENT
A
Inspection and Adjustment INFOID:0000000008944600

CLUTCH PEDAL INSPECTION AND ADJUSTMENT B

1. Check to see if the clutch pedal clevis pin (1) floats freely in the
bore of the clutch pedal (2). It should not be bound by the clevis
(3) or clutch pedal. CL
a. If the clevis pin is not free, check that the pedal stopper bolt (A)
is not applying pressure to the clutch pedal causing the clevis
pin to bind. To adjust, loosen the pedal stopper bolt lock nut (B) D
and turn the pedal stopper bolt.
b. Tighten the lock nut.
c. Verify that the clutch pedal clevis pin floats freely in the bore of E
the clutch pedal. It should not be bound by the clevis or clutch
pedal.
d. If the clevis pin is still not free, remove the clevis pin and check F
for deformation or damage. Replace the pin if necessary. Leave
the pin removed for step 2.
2. Check the clutch pedal stroke for free range of movement.
G
a. With the clutch pedal clevis pin removed, manually move the
pedal up and down to determine if it moves freely.
b. If any sticking is noted, replace the related parts (clutch pedal,
H
pedal bracket, assist spring, bushing, etc.). Reassemble the
pedal and re-verify that the clevis pin floats freely in the bore of
the pedal.
3. Check the clutch hydraulic system components (clutch master
AWDIA0513GB
I
cylinder, clutch operating cylinder, Clutch withdrawal lever, clutch release bearing, etc.) for sticking or
binding.
a. If any sticking or binding is noted, repair or replace the related parts as necessary. J
b. If any hydraulic system repair was necessary, bleed the clutch hydraulic system by following the bleeding
procedure.
K
BLEEDING PROCEDURE
CAUTION:
• Carefully monitor the fluid level at the clutch master cylinder during the bleeding operation.
• Do not splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on L
painted areas, wash it away with water immediately.
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or M
power bleeder will not purge all of the air from the system.
1. Top off the clutch master cylinder reservoir with the recommended brake fluid "DOT 3".
2. Connect a transparent vinyl tube to the air bleeder valve on the N
clutch operating cylinder as shown.
3. Slowly depress the clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 sec- O
onds intervals.
4. With the clutch pedal fully depressed, open the air bleeder valve
to release the air.
P
5. Close the air bleeder valve.
6. Release the clutch pedal and wait at least 5 seconds.
7. Repeat steps 3 through 6 above until no more air bubbles are in SCL203-A
the brake fluid coming out of the vinyl tube attached to the air
bleeder valve.
8. Close the air bleeder valve and tighten to specification.

Revision: April 2013 CL-5 2013 D22 LCV

 INSPECTION AND ADJUSTMENT
< SERVICE INFORMATION >

Air bleeder valve : Refer to CL-10, "Component".

Revision: April 2013 CL-6 2013 D22 LCV

 CLUTCH PEDAL
< SERVICE INFORMATION >
CLUTCH PEDAL
A
Component INFOID:0000000008944601

CL

I
AWDIA0515GB

1. Clutch pedal bracket 2. Fulcrum pin 3. Lock nut J

4. Pedal stopper bolt 5. Clevis pin 6. Pedal stopper rubber
7. Clutch pedal 8. Snap pin 9. Bushing
10. Assist spring A. Refer to CL-8, "Component". K
: Apply lithium-based grease including molybdenum disulphide.

Removal and Installation INFOID:0000000008944602 L

REMOVAL
1. Remove the clutch master cylinder nuts from inside the engine compartment. M
2. Remove the instrument lower panel LH. Refer to IP-10, "Removal and Installation".
3. Remove the snap pin and clevis pin from the clutch pedal.
4. Remove the clutch pedal bracket bolts and the clutch pedal assembly. N

INSTALLATION
Installation is in the reverse order of removal. O
• After installation, inspect and adjust the clutch pedal. Refer to CL-5, "Inspection and Adjustment".

Revision: April 2013 CL-7 2013 D22 LCV

 CLUTCH MASTER CYLINDER
< SERVICE INFORMATION >
CLUTCH MASTER CYLINDER
Component INFOID:0000000008944603

AWDIA0514GB

1. Reservoir cap 2. Reservoir 3. Seal

4. Cylinder body 5. Push rod 6. Stopper
7. Stopper ring 8. Seat 9. Lock nut
10. Clevis 11. Piston assembly 12. Piston cup
13. Return spring 14. Spring pin
r: Apply rubber lubricant. S: Apply silicone grease.

Removal and Installation INFOID:0000000008944604

CAUTION:
Do not spill brake fluid onto painted surfaces. If it spills, wipe it up immediately and wash the affected
area with water.
REMOVAL
1. Remove the snap pin and clevis pin from the clevis, then separate from the clutch pedal.
2. Drain the brake fluid from the clutch hydraulic system.
3. Remove the clutch tube from the clutch master cylinder using suitable tool.
4. Remove the clutch master cylinder nuts and the clutch master cylinder.
INSTALLATION
Installation is in the reverse order of removal.
• After installation, inspect and adjust the clutch pedal as necessary and bleed the clutch hydraulic system.
Refer to CL-5, "Inspection and Adjustment".
Disassembly and Assembly INFOID:0000000008944605

DISASSEMBLY
1. Remove the spring pin using suitable tool.
2. Remove the reservoir and seal from the cylinder body.
3. Remove the clevis and lock nut, if necessary.
4. Remove the seat, stopper ring, stopper and push rod.
CAUTION:
Carefully remove the push rod to prevent it from popping out and becoming damaged.
NOTE:

Revision: April 2013 CL-8 2013 D22 LCV

 CLUTCH MASTER CYLINDER
< SERVICE INFORMATION >
Remove stopper ring using suitable tool while pushing push rod into cylinder body.
5. Remove the piston assembly and return spring. A

ASSEMBLY
Assembly is in the reverse order of disassembly.
• When installing stopper ring, tap in lightly while pushing push rod into cylinder body. B
CAUTION:
• Firmly hold the push rod into cylinder body to prevent it from popping out and becoming damaged.
• Do not reuse stopper ring. CL
Inspection INFOID:0000000008944606

Check the following items, and replace if necessary. D

• Rubbing surface of cylinder and piston, for uneven wear, rust or damage
• Piston with piston cup, for wear or damage
• Return spring, push rod, stopper and seat for wear or damage E
• Reservoir, for deformation or damage

Revision: April 2013 CL-9 2013 D22 LCV

 OPERATING CYLINDER
< SERVICE INFORMATION >
OPERATING CYLINDER
Component INFOID:0000000008944607

AWDIA0516GB

1. Clutch hose 2. Copper sealing washer 3. Cylinder body

4. Piston spring 5. Piston cup 6. Piston assembly
7. Dust cover 8. Push rod 9. Air bleeder valve
R: Apply rubber grease. r: Apply rubber lubricant. S: Apply silicone grease.

Removal and Installation INFOID:0000000008944608

CAUTION:
Do not spill brake fluid on painted surfaces. If it spills, wipe up immediately and wash the affected area
with water.
REMOVAL
1. Drain the brake fluid from the clutch hydraulic system.
2. Remove the clutch hose and copper sealing washer from the operating cylinder.
CAUTION:
Do not reuse copper sealing washer.
3. Remove the operating cylinder bolts and the operating cylinder.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• Make sure the clutch hose is not bent or twisted.
• Do not reuse copper sealing washers.
• After installation, bleed the clutch hydraulic system. Refer to CL-5, "Inspection and Adjustment".
Disassembly and Assembly INFOID:0000000008944609

DISASSEMBLY

Revision: April 2013 CL-10 2013 D22 LCV

 OPERATING CYLINDER
< SERVICE INFORMATION >
• Remove the dust cover, push rod, piston assembly and piston spring from the cylinder body.
A
ASSEMBLY
1. Apply rubber lubricant to the cylinder body inner surface and rubber grease to the piston cup and piston.
2. Insert the piston assembly and piston spring into the cylinder body. B
3. Apply rubber grease to the dust cover and install the push rod and dust cover.
Inspection INFOID:0000000008944610
CL
Check the following items, and replace if necessary.
• Rubbing surface of cylinder and piston, for uneven wear, rust or damage
• Piston assembly (piston with piston cup), for wear or damage D
• Piston spring, for wear or damage
• Push rod, for wear or damage
• Dust cover, for cracks, deformation or damage
E

Revision: April 2013 CL-11 2013 D22 LCV

 CLUTCH PIPING
< SERVICE INFORMATION >
CLUTCH PIPING
Component INFOID:0000000008944611

AWDIA0520GB

1. Clutch pedal 2. Clutch master cylinder 3. Clutch pipe

4. Connector (if equipped) 5. Clip 6. Clutch hose
7. Operating Cylinder

Removal and Installation INFOID:0000000008944612

Carefully observe the following during clutch tube removal and installation.
CAUTION:
• Do not spill brake fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected
area with water.
• Do not reuse the copper sealing washer.
• Do not damage the clutch hose, clutch tube or fittings.
• Make sure the clutch hose is not bent or twisted.
• After installation, bleed the air from the clutch hydraulic system. Refer to CL-5, "Inspection and Adjustment".

Revision: April 2013 CL-12 2013 D22 LCV

 CLUTCH RELEASE MECHANISM
< SERVICE INFORMATION >
CLUTCH RELEASE MECHANISM
A
Component INFOID:0000000008944613

CL

G
WCIA0441E

1. Holder spring 2. Release bearing sleeve 3. Release bearing

4. Withdrawal lever 5. Dust cover 6. Retainer spring
H

Removal and Installation INFOID:0000000008944614

I
REMOVAL
1. Remove the transmission. Refer to MT-11, "Removal and Installation".
2. Remove the release bearing sleeve assembly, holder spring, and withdrawal lever from inside the clutch J
housing.
3. Remove the dust cover.
4. Remove the retainer spring from the withdrawal lever. K
5. Remove the release bearing from the release bearing sleeve
using suitable tool.
L

CL145

O
INSTALLATION
Installation is in the reverse order of removal.

Revision: April 2013 CL-13 2013 D22 LCV

 CLUTCH RELEASE MECHANISM
< SERVICE INFORMATION >
• When installing release bearing to release bearing sleeve, use
suitable drift.

WCL025

• Install retainer spring and holder spring as shown.

SCL217

• Clean old grease and abrasive materials off the grease application areas and apply grease to the specified
points as shown.

WCL043

• Apply approximately 1 mm (0.04 in) thick coat of grease to withdrawal lever and holder spring frictional sur-
faces.
• Apply a coat of grease to ball pin contact surface of the withdrawal lever and inner slots of the release bear-
ing. The grease surface should be level with the surrounding area.
• Apply a thin coat of clutch sleeve grease to the release bearing frictional surface. After grease application,
install release bearing and wipe off excess grease forced out during bearing installation.
CAUTION:
• Do not bring any grease into contact with the clutch disc facing, pressure plate surface, or flywheel
surface.
• Before installing transmission to the vehicle, check that each sliding surface slides smoothly by
operating the withdrawal lever.
Inspection INFOID:0000000008944615

Check the following items, and replace if necessary.

Revision: April 2013 CL-14 2013 D22 LCV

 CLUTCH RELEASE MECHANISM
< SERVICE INFORMATION >
• Release bearing, for faulty rotation, damage and proper alignment
• Release bearing sleeve, for wear, rust or damage A
• Withdrawal lever, for wear, rust or damage
• Dust seal, for deformation or cracks
B

CL

SCL733

Revision: April 2013 CL-15 2013 D22 LCV

 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
< SERVICE INFORMATION >
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Component INFOID:0000000008944616

AWDIA0518GB

1. Flywheel 2. Clutch disc 3. Clutch cover

A. Refer to CL-16, "Removal and Installation".
: Apply lithium-based grease including molybdenum disulphide.

Removal and Installation INFOID:0000000008944617

CAUTION:
• Do not clean the clutch disc with solvent.
• When installing, do not get grease from the main drive shaft onto the clutch disc friction surface.
REMOVAL
1. Remove the manual transmission from the vehicle. Refer to MT-11, "Removal and Installation".
2. Remove the clutch cover bolts using power tool and the clutch cover and clutch disc.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Do not allow grease to contaminate the clutch facing.
• When installing clutch disc and clutch cover, install the Tool and
pre-tighten the bolts. Then tighten the clutch cover bolts according
to the following.

Tool number : ST20630000 (J-26366)

WCIA0172E

Revision: April 2013 CL-16 2013 D22 LCV

 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
< SERVICE INFORMATION >
- Tighten the clutch cover bolts to the specified torque in two steps in
numerical order as shown. A

Step 1 : 10 - 20 N·m (1.0 - 2.0 kg-m, 7 - 15 ft-lb)

Step 2 : 22 - 29 N·m (2.2 - 3.0 kg-m, 16 - 21 ft-lb) B

CL

AWDIA0519ZZ

D
Inspection and Adjustment INFOID:0000000008944618

CLUTCH DISC E
Check the following items, and replace if necessary.
• Clutch disc, for burns, discoloration, oil or grease leakage
• Clutch disc, for wear of facing
F
Facing wear : Refer to CL-19, "Clutch Disc".

H
ACL063

• Clutch disc, for runout of facing and backlash of spline.

I
Runout and backlash : Refer to CL-19, "Clutch Disc".
J

ACL064
L
CLUTCH COVER
• Check clutch cover, installed on vehicle, for uneven diaphragm
spring toe height. If unevenness exceeds the limit, adjust the dia- M
phragm spring toe height using Tool.

Uneven limit of diaphragm : Refer to CL-19, "Clutch N

spring toe height Cover".

Tool number : ST20050240 ( — ) O

SCL466

P
FLYWHEEL
CAUTION:
Do not allow any magnetic materials to contact the ring gear teeth.
• Inspect contact surface of flywheel for slight burns or discoloration. Clean flywheel with emery paper.

Revision: April 2013 CL-17 2013 D22 LCV

 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
< SERVICE INFORMATION >
• Check flywheel runout. Refer to EM-55, "Inspection".

AEM100

Revision: April 2013 CL-18 2013 D22 LCV

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION >
SERVICE DATA AND SPECIFICATIONS (SDS)
A
Clutch Control System INFOID:0000000008944619

B
Type of clutch control Hydraulic

Clutch Master Cylinder (with clutch damper) INFOID:0000000008944620

CL

Inner diameter 15.87 mm (5/8 in)

D
Clutch Operating Cylinder INFOID:0000000008944621

Unit: mm (in)
E
Inner diameter 17.46 (11/16)

Clutch Disc INFOID:0000000008944622

F
Unit: mm (in)

Model 240
Facing size 240 x 150 x 3.5 G
(Outer dia. x inner dia. x thickness) (9.45 x 5.91 x 0.138)
7.75 - 8.25 (0.305 - 0.3248)
Thickness of disc assembly with load
with 4,903 N (500 kg, 1,103 lb) H
Wear limit of facing surface to rivet head 0.3 (0.012)
Runout limit of facing 1.0 (0.039)
I
Distance of runout check point (from hub center) 115 (4.53)
Maximum backlash of spline (at outer edge of disc) 1.0 (0.039)

Clutch Cover INFOID:0000000008944623 J

Model 240 K
2WD 4,903 N (500 kg, 1,103 lb)
Set-load
4WD 4,658 N (475 kg, 1,047 lb)
Diaphragm spring height 38.5 mm (1.516 in)
L

Uneven limit of diaphragm spring toe height 0.7 mm (0.028 in)

Revision: April 2013 CL-19 2013 D22 LCV