TRANSMISSION & DRIVELINE

CL
A

B
SECTION
CLUTCH C

CL

E
CONTENTS
SYMPTOM DIAGNOSIS ............................... 3 OPERATING CYLINDER .................................. 13 F
Exploded View .........................................................13
NOISE, VIBRATION AND HARSHNESS Removal and Installation .........................................13
(NVH) TROUBLESHOOTING ............................. 3 G
NVH Troubleshooting Chart ...................................... 3 CLUTCH PIPING ............................................... 14
Exploded View .........................................................14
PRECAUTION ............................................... 4 Removal and Installation .........................................14
H
PRECAUTIONS ................................................... 4 UNIT REMOVAL AND INSTALLATION ...... 15
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- CLUTCH RELEASE MECHANISM ................... 15 I
SIONER" ................................................................... 4
5M/T ...........................................................................15
Precaution for Procedure without Cowl Top Cover...... 4
5M/T : Exploded View ..............................................15
Service Notice or Precautions ................................... 4
5M/T : Removal and Installation ..............................15 J
PREPARATION ............................................ 6 5M/T : Inspection .....................................................16

PREPARATION ................................................... 6 6M/T ...........................................................................16

6M/T : Exploded View ..............................................17 K
Special Service Tool ................................................. 6
6M/T : Removal and Installation ..............................17
Commercial Service Tool .......................................... 6
6M/T : Inspection .....................................................18
PERIODIC MAINTENANCE .......................... 8 L
CLUTCH DISC, CLUTCH COVER .................... 20
CLUTCH PEDAL ................................................. 8 5M/T ...........................................................................20
On-Vehicle Inspection and Adjustment ..................... 8 M
5M/T : Exploded View ..............................................20
CLUTCH FLUID ................................................... 9 5M/T : Removal and Installation ..............................20
Bleeding .................................................................... 9 5M/T : Inspection after Removal ..............................21
5M/T : Adjustment after Installation .........................22 N
REMOVAL AND INSTALLATION ............... 10
6M/T ...........................................................................22
CLUTCH PEDAL ................................................10 6M/T : Exploded View ..............................................22
Exploded View ........................................................ 10 6M/T : Removal and Installation ..............................23 O
Removal and Installation ......................................... 10 6M/T : Inspection after Removal ..............................23
Inspection ................................................................ 10 6M/T : Adjustment after Installation .........................24
P
CLUTCH MASTER CYLINDER ..........................11 SERVICE DATA AND SPECIFICATIONS
Exploded View ........................................................ 11 (SDS) ............................................................ 25
Removal and Installation ......................................... 11
SERVICE DATA AND SPECIFICATIONS
CLUTCH RESERVOIR .......................................12 (SDS) ................................................................. 25
Removal and Installation ......................................... 12 Clutch Control System .............................................25
Clutch Master Cylinder ............................................25

Revision: March 2012 CL-1 2011 Frontier

Clutch Operating Cylinder ...................................... 25 Clutch Cover ........................................................... 25
Clutch Disc ............................................................. 25 Clutch Pedal ............................................................ 26

Revision: March 2012 CL-2 2011 Frontier

 Symptom
CLUTCH

Reference page

Clutch slips

Revision: March 2012

Clutch noisy
Clutch pedal spongy
Clutch grabs/chatters
< SYMPTOM DIAGNOSIS >

SUSPECTED PARTS (Possible cause)

Clutch does not disengage

NVH Troubleshooting Chart

CLUTCH PEDAL (Inspection and adjustment) CL-8

1
1
CLUTCH LINE (Air in line) CL-9

2
1
SYMPTOM DIAGNOSIS

MASTER CYLINDER PISTON CUP (Damaged) BR-48

3
2
tion. If necessary, repair or replace these parts.

OPERATING CYLINDER PISTON CUP (Damaged) CL-13

4
2
EM-77 (QR25DE),
ENGINE MOUNTING (Loose)

1
EM-216 (VQ40DE)

CL-3
CL-15 (5M/T),
RELEASE BEARING (Worn, dirty or damaged)

1
CL-17 (6 M/T)
CLUTCH DISC (Out of true)

5
CLUTCH DISC (Runout is excessive)

5
2
CLUTCH DISC (Lining broken)

5
CLUTCH DISC (Dirty or burned)

5
CLUTCH DISC (Oily)

5
2

2
CL-20 (5M/T),
CLUTCH DISC (Worn out)

2
CL-22 (6M/T)
CLUTCH DISC (Hardened)
2 CLUTCH DISC (Lack of spline grease)

5
DIAPHRAGM SPRING (Damaged)

6
3
DIAPHRAGM SPRING (Out of tip alignment)

6
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

PRESSURE PLATE (Distortion)

7
4

EM-91 (QR25DE),
FLYWHEEL (Distortion)
5

2011 Frontier
EM-231 (VQ40DE)
INFOID:0000000006251264

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-

L
F

P
K
E
B
A

N
CL

H
C

O
G

M
 PRECAUTIONS
< PRECAUTION >
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000006251265

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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SR and SB section of this Service Man-
ual.
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 SR 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 for Procedure without Cowl Top Cover INFOID:0000000006251266

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

PIIB3706J

Service Notice or Precautions INFOID:0000000006251267

• Always use recommended fluid. Refer to MA-16, "FOR USA AND CANADA : Fluids and Lubricants".
• Never reuse drained fluid.
• Be careful not to splash fluid on painted areas.

Revision: March 2012 CL-4 2011 Frontier

 PRECAUTIONS
< PRECAUTION >
• When removing and installing clutch piping, use tool.
• Use new fluid to clean or wash all parts of master cylinder. A
• Never use mineral oils such as gasoline or kerosene. It will ruin the
rubber parts of the hydraulic system.
WARNING: B
After cleaning clutch disc, wipe it with a dust collector. Do not
use compressed air.
C

SBR686C

CL

Revision: March 2012 CL-5 2011 Frontier

 PREPARATION
< PREPARATION >
PREPARATION
PREPARATION
Special Service Tool INFOID:0000000006251268

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
(Kent-Moore No.)
Tool name
ST20050240 Adjusting unevenness of diaphragm spring of
( — ) clutch cover
Diaphragm adjusting wrench

ZZA0508D

ST20630000 Installing clutch disc

(J-26366) a: 15.8 mm (0.622 in) dia.
Clutch aligning bar b: 22.9 mm (0.902 in) dia.

ZZA1178D

Commercial Service Tool INFOID:0000000006251269

Tool name Description

Power tool Loosening bolts, nuts and screws

PIIB1407E

1. Flare nut crowfoot Removing and installing clutch piping

2. Torque wrench a: 10 mm (0.39 in)

S-NT360

Revision: March 2012 CL-6 2011 Frontier

 PREPARATION
< PREPARATION >
Tool name Description
A
Bearing puller Removing release bearing

C
NT077

Bearing drift Installing release bearing

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

NT474

Revision: March 2012 CL-7 2011 Frontier

 CLUTCH PEDAL
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCE
CLUTCH PEDAL
On-Vehicle Inspection and Adjustment INFOID:0000000006251270

1. Check to see if the clevis pin floats freely in the bore of the
clutch pedal. It should not be bound by the clevis or clutch pedal.
a. If the clevis pin is not free, check that the pedal stopper bolt or
ASCD clutch switch is not applying pressure to the clutch pedal
causing the clevis pin to bind. To adjust, loosen the lock nut and
turn the pedal stopper bolt or ASCD clutch switch.
b. Tighten the lock nut to the specified torque. Refer to CL-10,
"Exploded View".
c. Verify that the clevis pin floats in the bore of the clutch pedal. It
should not be bound by the clutch pedal.
PCIB0907E
d. If the clevis pin is still not free, remove the clevis pin and check
for deformation or damage. Replace clevis pin if necessary. Leave pin removed for step 2.
2. Check clutch pedal stroke for free range of movement.
a. With the clevis pin removed, manually move the clutch pedal up and down to determine if it moves freely.
b. If any sticking is noted, replace the assembly.
3. Adjust clearance “(C) while depressing clutch pedal fully. (With
clutch interlock switch)

Clearance (C) : 0.1 - 1.0 mm (0.004 - 0.039 in)

4. Check clutch hydraulic and system components (clutch master
cylinder, clutch operating cylinder, clutch withdrawal lever and
clutch release bearing) for sticking or binding.
a. If any sticking or binding noted, repair or replace related parts as
necessary.
b. If hydraulic system repair was necessary, bleed the clutch
hydraulic system. Refer to CL-9, "Bleeding".

SCL800

Revision: March 2012 CL-8 2011 Frontier

 CLUTCH FLUID
< PERIODIC MAINTENANCE >
CLUTCH FLUID
A
Bleeding INFOID:0000000006251271

CAUTION: B
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected
area with water.
NOTE:
Monitor the fluid level in the reservoir tank to make sure it does not empty. C
1. Top off reservoir with new recommended brake fluid. Refer to MA-16, "FOR USA AND CANADA : Fluids
and Lubricants".
2. Connect a transparent vinyl tube and container to the air bleeder CL
valve on the clutch operating cylinder.
3. Fully depress the clutch pedal several times.
4. With the clutch pedal depressed, open the bleeder valve to E
release the air.
5. Close the bleeder valve.
6. Repeat steps 3 to 5 until clear brake fluid comes out of the air F
bleeder valve.
7. Tighten the air bleeder to the specified torque.
SCL203-A
G
Air bleeder 7.9 N·m (0.81 kg-m, 70 in-lb)
H

Revision: March 2012 CL-9 2011 Frontier

 CLUTCH PEDAL
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
CLUTCH PEDAL
Exploded View INFOID:0000000006251272

WCIA0548E

1. Bracket 2. Bushing 3. Snap pin

4. Pedal stopper rubber 5. Clutch interlock switch 6. Clutch pedal
7. Stopper rubber 8. ASCD clutch switch (with ASCD) 9. Pedal stopper bolt (without ASCD)
10. Clevis pin

Removal and Installation INFOID:0000000006251273

REMOVAL
1. Remove the clutch pedal bracket nuts from inside the engine compartment.
2. Disconnect the clutch interlock switch and ASCD clutch switch (if equipped), then remove the wiring har-
ness from the pedal assembly.
3. Remove the snap pin and clevis pin.
4. Remove the pedal bracket bolt and then remove the clutch pedal assembly.
INSTALLATION
Installation is in the reverse order of removal.
NOTE:
Tighten the pedal stopper bolt lock nut or ASCD clutch switch lock nut to the specified torque after installing
the clutch pedal assembly in the vehicle and adjusting the pedal free play.
Inspection INFOID:0000000006251274

INSPECTION AFTER REMOVAL

• Inspect the clutch pedal for bends, damage, or cracked welds. Replace if necessary.
• Make sure that the assist spring and return spring have not lost their spring. Replace if necessary.

Revision: March 2012 CL-10 2011 Frontier

 CLUTCH MASTER CYLINDER
< REMOVAL AND INSTALLATION >
CLUTCH MASTER CYLINDER
A
Exploded View INFOID:0000000008180419

CL

G
AWDIA0936GB

1. Clamp 2. Reservoir hose 3. Clamp

4. Cylinder body 5. Clutch tube A. To reservoir tank
H

Removal and Installation INFOID:0000000006251275

I
CAUTION:
Do not spill brake fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected
area with water.
NOTE: J
When removing components such as hoses, tubes/lines, ect., cap or plug openings to prevent fluid from spill-
ing.
K
REMOVAL
1. Remove the snap pin and clevis pin from the clevis, and separate it from the clutch pedal.
2. Remove the hose clamp and hose from the clutch master cylinder. L
3. Remove the clutch tube using suitable tool.
4. Remove the clutch master cylinder nuts, and remove the clutch master cylinder from the vehicle.
INSTALLATION M
Installation is in the reverse order of removal.
• Before installation, check the position of the clevis and push rod. If
(L) is outside standard length, adjust the position of the clevis and N
push rod.

Length (L) O
QR25DE : 119.5 mm (4.70 in)
VQ40DE : 120.5 mm (4.74 in)
• After installation, inspect and adjust the clutch pedal as necessary, P
then bleed the clutch hydraulic system. Refer to CL-8, "On-Vehicle
Inspection and Adjustment" and CL-9, "Bleeding". SCIA5158E

Revision: March 2012 CL-11 2011 Frontier

 CLUTCH RESERVOIR
< REMOVAL AND INSTALLATION >
CLUTCH RESERVOIR
Removal and Installation INFOID:0000000006251276

For removal and installation of clutch reservoir, refer to BR-33, "Removal and Installation".
NOTE:
• Be sure to check clutch fluid after installation. Refer to BR-21, "Drain and Refill".
• Be sure to bleed clutch system after installation. Refer to CL-9, "Bleeding".

Revision: March 2012 CL-12 2011 Frontier

 OPERATING CYLINDER
< REMOVAL AND INSTALLATION >
OPERATING CYLINDER
A
Exploded View INFOID:0000000008180423

CL

G
AWDIA0934GB

1. Operating cylinder 2. Copper sealing washer 3. Clutch hose

4. Air bleeder
H

Removal and Installation INFOID:0000000006251277

I
CAUTION:
Do not spill brake fluid on painted surfaces. If it spills, wipe up immediately and wash the affected area
with water.
NOTE: J
When removing components such as hoses, tubes/lines, ect., cap or plug openings to prevent fluid from spill-
ing.
K
REMOVAL
1. Remove the clutch hose and copper sealing washer from the operating cylinder.
CAUTION:
Do not reuse the copper sealing washer. L
2. Remove the operating cylinder bolts, and remove the operating cylinder from the vehicle.
INSTALLATION M
Installation is in the reverse order of removal.
• Tighten the clutch hose fitting to the specified torque.
CAUTION:
• Make sure the clutch hose is not bent or twisted. N
• Do not reuse copper sealing washers.
• After installation, bleed the clutch hydraulic system. Refer to CL-9, "Bleeding".
O

Revision: March 2012 CL-13 2011 Frontier

 CLUTCH PIPING
< REMOVAL AND INSTALLATION >
CLUTCH PIPING
Exploded View INFOID:0000000006251278

AWDIA0935GB

1. Clutch tube 2. Clutch orifice 3. Lock plate

4. Clutch hose 5. Operating Cylinder 6. Master cylinder
7. Clutch pedal

Removal and Installation INFOID:0000000006251279

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.
• When installing the clutch hose to the bracket, align the clutch
hose metal fittings with the bracket positioning emboss, then install
the lock plate to secure.
CAUTION:
• Do not damage the clutch hose.
• Make sure the clutch hose is not bent or twisted.
• Tighten the clutch tube and hose fittings to the specified torque.
CAUTION:
• Do not reuse the copper washer.
• Do not damage the clutch tube fittings or clutch tube.
• After installation, bleed the air from the clutch hydraulic system.
PCIB0681E
Refer to CL-9, "Bleeding".

Revision: March 2012 CL-14 2011 Frontier

 CLUTCH RELEASE MECHANISM
< UNIT REMOVAL AND INSTALLATION >
UNIT REMOVAL AND INSTALLATION A
CLUTCH RELEASE MECHANISM
5M/T
B
5M/T : Exploded View INFOID:0000000006251280

CL

H
WCIA0441E

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

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

5M/T : Removal and Installation INFOID:0000000006251281

J
REMOVAL
1. Remove the manual transmission from the vehicle. Refer to TM-20, "Removal and Installation from Vehi-
cle". K
2. Remove the release bearing sleeve assembly, holder spring, and withdrawal lever from inside the clutch
housing.
3. Remove the dust cover. L
4. Remove the retainer spring from the withdrawal lever.
5. Remove the release bearing from release bearing sleeve using
suitable tool. M

CLA0013D
P
INSTALLATION
Installation is in the reverse order of removal.
NOTE:

Revision: March 2012 CL-15 2011 Frontier

 CLUTCH RELEASE MECHANISM
< UNIT REMOVAL AND INSTALLATION >
• Install the release bearing to release bearing sleeve using suitable
tool, as shown.

WCL025

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

SCIA1362E

• Apply approximately 1 mm (0.04 in) thick coat of clutch sleeve grease to withdrawal lever and holder spring
frictional surfaces.
• Apply a coat of clutch sleeve grease to ball pin contact surface of the withdrawal lever and inner slots of the
release bearing. 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. Wipe off excess grease forced out during bearing installation.
CAUTION:
• Be careful not to bring any grease into contact with the clutch disc facing, pressure plate surface, or
flywheel surface.
• Before installing manual transmission to the vehicle, check that each sliding surface slides
smoothly by operating withdrawal lever.
5M/T : Inspection INFOID:0000000006251282

INSPECTION AFTER REMOVAL

• Replace the release bearing if it is seized, damaged, faulty in rota-
tion direction, or has poor aligning function.
• Replace the withdrawal lever if its contact surface is worn abnor-
mally.
• Replace the dust seal if it is deformed or cracked.

SCL733

6M/T

Revision: March 2012 CL-16 2011 Frontier

 CLUTCH RELEASE MECHANISM
< UNIT REMOVAL AND INSTALLATION >
6M/T : Exploded View INFOID:0000000006251283

CL

LCIA0373E

G
1. Holder spring 2. Release bearing sleeve 3. Release bearing
4. Withdrawal lever 5. Dust cover 6. Snap spring

6M/T : Removal and Installation INFOID:0000000006251284

H

REMOVAL
1. Remove the manual transmission from the vehicle. Refer to TM-71, "Removal and Installation from Vehi- I
cle (For 2WD Models)" or TM-73, "Removal and Installation from Vehicle (For 4WD Models)".
2. Remove the release bearing sleeve assembly, holder spring, and withdrawal lever from inside the clutch
housing. J
3. Remove the dust cover.
4. Remove the snap spring from the withdrawal lever.
K
5. Remove the release bearing from release bearing sleeve using
suitable tool.

N
CLA0013D

INSTALLATION
Installation is in the reverse order of removal. O
NOTE:

Revision: March 2012 CL-17 2011 Frontier

 CLUTCH RELEASE MECHANISM
< UNIT REMOVAL AND INSTALLATION >
• Install the release bearing to release bearing sleeve using suitable
tool, as shown.

WCL025

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

SCIA1362E

• Apply approximately 1 mm (0.04 in) thick coat of clutch sleeve grease to withdrawal lever and holder spring
frictional surfaces.
• Apply a coat of clutch sleeve grease to ball pin contact surface of the withdrawal lever and inner slots of the
release bearing. 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. Wipe off excess grease forced out during bearing installation.
CAUTION:
• Before installing the manual transmission to the vehicle, check that each sliding surface slides
smoothly by operating withdrawal lever.
• Be careful not to bring any grease into contact with the clutch disc facing, pressure plate surface, or
flywheel surface.
• When assembling, make sure that both ends of the snap
spring touch the end face of the withdrawal lever.
• Be careful with the orientation of the installation.

SCIA6903E

6M/T : Inspection INFOID:0000000006251285

INSPECTION AFTER REMOVAL

Revision: March 2012 CL-18 2011 Frontier

 CLUTCH RELEASE MECHANISM
< UNIT REMOVAL AND INSTALLATION >
• Replace the release bearing if it is seized, damaged, faulty in rota-
tion direction, or has poor aligning function. A
• Replace the withdrawal lever if its contact surface is worn abnor-
mally.
• Replace the dust seal if it is deformed or cracked.
B

SCL733

CL

Revision: March 2012 CL-19 2011 Frontier

 CLUTCH DISC, CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
CLUTCH DISC, CLUTCH COVER
5M/T
5M/T : Exploded View INFOID:0000000006251286

WCIA0522E

1. Flywheel 2. Clutch disc 3. Clutch cover

5M/T : Removal and Installation INFOID:0000000006251287

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 TM-20, "Removal and Installation from Vehi-
cle".
2. Remove the clutch cover bolts using power tool. Remove the clutch cover and clutch disc.
INSTALLATION
1. Apply recommended grease to clutch disc and main drive shaft spline.
CAUTION:
Do not allow grease to contaminate the clutch facing.

Revision: March 2012 CL-20 2011 Frontier

 CLUTCH DISC, CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
2. Install clutch disc and clutch cover. Pre-tighten the bolts and
install Tool. Then tighten the clutch cover bolts evenly in two A
steps to the specified torque in the order shown. Refer to CL-20,
"5M/T : Exploded View".
B
Tool number : ST20630000 (J-26366)

CL

G
WCIA0504E

3. Install the manual transmission. Refer to TM-20, "Removal and Installation from Vehicle".
H
5M/T : Inspection after Removal INFOID:0000000006251288

INSPECTION AFTER REMOVAL

I
Clutch Disc
• Check the wear of the clutch disc facing.
J
Clutch disc facing : Refer to CL-25, "Clutch Disc".
wear
K

SCL229

M
• Check the runout and backlash of the clutch disc. If the measure-
ment exceeds the specification, replace the clutch disc.
N
Runout and backlash : Refer to CL-25, "Clutch Disc".

P
SCL221

Clutch Cover
• Check clutch cover thrust ring for wear or damage. If wear or damage is found, replace clutch cover assem-
bly.
NOTE:
• Worn thrust ring will generate a beating noise when tapped at the rivet with a hammer.

Revision: March 2012 CL-21 2011 Frontier

 CLUTCH DISC, CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
• Broken thrust ring will make a clinking sound when cover is shaken up and down.
• If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with emery paper. If surface is damaged or distorted, replace the assembly.

Flywheel
• Check contact surface of flywheel for slight burns or discoloration.
If any are found, repair flywheel with emery paper.
• Check the flywheel runout. Refer to EM-91, "Inspection After Dis-
assembly".

PBIC2168E

5M/T : Adjustment after Installation INFOID:0000000006251289

ADJUSTMENT AFTER INSTALLATION

Clutch Cover
With the clutch cover installed on the vehicle, check the diaphragm
spring toe height for unevenness. If unevenness exceeds the limit,
adjust the diaphragm spring toe height using Tool.

Uneven limit of diaphragm : Refer to CL-25, "Clutch

spring toe height Cover".

Tool number : ST20050240 ( — )

PCIB0276E

6M/T
6M/T : Exploded View INFOID:0000000006251290

WCIA0522E

1. Flywheel 2. Clutch disc 3. Clutch cover

Revision: March 2012 CL-22 2011 Frontier

 CLUTCH DISC, CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
6M/T : Removal and Installation INFOID:0000000006251291

A
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. B
• If the flywheel is removed, align the dowel pin with the smallest hole of flywheel. Refer to EM-221,
"Disassembly and Assembly".
REMOVAL C
1. Remove the manual transmission from the vehicle. Refer to TM-71, "Removal and Installation from Vehi-
cle (For 2WD Models)" or TM-73, "Removal and Installation from Vehicle (For 4WD Models)".
2. Remove the clutch cover bolts using power tool. Remove the clutch cover and clutch disc. CL
INSTALLATION
1. Apply recommended grease to clutch disc and main drive shaft spline.
CAUTION: E
Do not allow grease to contaminate the clutch facing.
2. Install clutch disc and clutch cover. Pre-tighten the bolts and
install Tool. Then tighten the clutch cover bolts evenly in two F
steps to the specified torque in the order shown. Refer to CL-22,
"6M/T : Exploded View".
G
Tool number : ST20630000 (J-26366)

L
LCIA0391E

3. Install the manual transmission. Refer to TM-71, "Removal and Installation from Vehicle (For 2WD Mod-
els)" or TM-73, "Removal and Installation from Vehicle (For 4WD Models)". M

6M/T : Inspection after Removal INFOID:0000000006251292

N
INSPECTION AFTER REMOVAL
Clutch Disc
• Check the wear of the clutch disc facing. O

Clutch disc facing : Refer to CL-25, "Clutch Disc".

wear P

SCL229

Revision: March 2012 CL-23 2011 Frontier

 CLUTCH DISC, CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
• Check the runout and backlash of the clutch disc. If the measure-
ment exceeds the specification, replace the clutch disc.

Runout and backlash : Refer to CL-25, "Clutch Disc".

SCL221

Clutch Cover
• Check clutch cover thrust ring for wear or damage. If wear or damage is found, replace clutch cover assem-
bly.
NOTE:
• Worn thrust ring will generate a beating noise when tapped at the rivet with a hammer.
• Broken thrust ring will make a clinking sound when cover is shaken up and down.
• If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with emery paper. If surface is damaged or distorted, replace the assembly.

Flywheel
• Check contact surface of flywheel for slight burns or discoloration.
If any are found, repair flywheel with emery paper.
• Check the flywheel runout. Refer to EM-231, "Inspection After Dis-
assembly".

PBIC2168E

6M/T : Adjustment after Installation INFOID:0000000006251293

ADJUSTMENT AFTER INSTALLATION

With the clutch cover installed on the vehicle, check the diaphragm
spring toe height for unevenness. If unevenness exceeds the limit,
adjust the diaphragm spring toe height using Tool.

Uneven limit of diaphragm : Refer to CL-25, "Clutch

spring toe height Cover".

Tool number : ST20050240 ( — )

PCIB0276E

Revision: March 2012 CL-24 2011 Frontier

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
SERVICE DATA AND SPECIFICATIONS (SDS)
Clutch Control System INFOID:0000000006251294
B

Type of clutch control Hydraulic

C
Clutch Master Cylinder INFOID:0000000006251295

Unit: mm (in) CL
Inner diameter 15.87 (5/8)

Clutch Operating Cylinder INFOID:0000000006251296

E
Unit: mm (in)

Inner diameter 19.05 (3/4)

F
Clutch Disc INFOID:0000000006251297

Unit: mm (in) G
Engine model QR25DE VQ40DE
Model 240 260
Transmission Model 5 M/T 6 M/T
H

Facing size (Outer dia. × inner dia. × thickness) 240 × 160 × 3.5 (9.45 × 6.30 × 0.138) 260 × 190 × 3.2 (10.24 × 7.48 × 0.126)
Wear limit (depth to rivet head) 0.3 (0.012)
I
Runout limit/diameter of the area to be measured 0.7 (0.028) or less/230 (9.06) dia. 1.0 (0.039) or less/250 (9.84) dia.
Maximum backlash of spline (at outer disc edge) 1.0 (0.039)
J
Clutch Cover INFOID:0000000006251298

Unit: mm (in)
Engine model QR25DE VQ40DE
K
Transmission Model 5 M/T 6 M/T
Set-load 5890 N (600 kg, 1324 lb) 8340 N (850 kg, 1875 lb) L
Diaphragm spring lever height 37.0 - 39.0 (1.457 - 1.535) 44.0 - 46.0 (1.732 - 1.811)
Uneven limit of diaphragm spring toe height 0.7 (0.028)
M

Revision: March 2012 CL-25 2011 Frontier

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Clutch Pedal INFOID:0000000006251299

Unit: mm (in)

SCL800

Clearance (C) between pedal stopper rubber and clutch interlock switch threaded end
0.1 - 1.0 (0.004 - 0.039)
while clutch pedal is fully depressed.

Revision: March 2012 CL-26 2011 Frontier