TRANSMISSION & DRIVELINE

SECTION CL CLUTCH
B

CL

E
CONTENTS
SYMPTOM DIAGNOSIS ............................... 3 Exploded View .........................................................12 F
Removal and Installation .........................................12
NOISE, VIBRATION AND HARSHNESS Disassembly and Assembly .....................................12
(NVH) TROUBLESHOOTING ............................. 3 Inspection ................................................................13 G
NVH Troubleshooting Chart ...................................... 3
CLUTCH PIPING ............................................... 14
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PRECAUTION ............................................... 4 Exploded View .........................................................14

Removal and Installation .........................................14 H
PRECAUTIONS ................................................... 4
Precaution for Supplemental Restraint System REMOVAL AND INSTALLATION ............... 15
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- I
SIONER" ................................................................... 4 CLUTCH RELEASE MECHANISM ................... 15
Precaution for Procedure without Cowl Top Cover...... 4
5M/T ...........................................................................15
Service Notice or Precautions ................................... 4
5M/T : Exploded View ..............................................15 J
PREPARATION ............................................ 5 5M/T : Removal and Installation ..............................15
5M/T : Inspection .....................................................16
PREPARATION ................................................... 5 K
6M/T ...........................................................................16
Special Service Tool ................................................. 5
6M/T : Exploded View ..............................................17
Commercial Service Tool .......................................... 5
6M/T : Removal and Installation ..............................17
ON-VEHICLE MAINTENANCE ..................... 7 6M/T : Inspection .....................................................18 L

CLUTCH PEDAL ................................................. 7 CLUTCH DISC, CLUTCH COVER .................... 20

On-Vehicle Inspection and Adjustment ..................... 7 5M/T ...........................................................................20 M
CLUTCH FLUID ................................................... 8 5M/T : Exploded View ..............................................20
Bleeding .................................................................... 8 5M/T : Removal and Installation ..............................20
5M/T : Inspection and Adjustment ...........................21 N
ON-VEHICLE REPAIR .................................. 9 6M/T ...........................................................................22
CLUTCH PEDAL ................................................. 9 6M/T : Exploded View ..............................................22
Exploded View .......................................................... 9 6M/T : Removal and Installation ..............................22 O
Removal and Installation ........................................... 9 6M/T : Inspection and Adjustment ...........................23
Inspection .................................................................. 9
SERVICE DATA AND SPECIFICATIONS P
CLUTCH MASTER CYLINDER ..........................10 (SDS) ............................................................ 25
Exploded View ........................................................ 10
Removal and Installation ......................................... 10 SERVICE DATA AND SPECIFICATIONS
Disassembly and Assembly .................................... 11 (SDS) ................................................................. 25
Inspection ................................................................ 11 Clutch Control System .............................................25
Clutch Master Cylinder ............................................25
OPERATING CYLINDER ...................................12 Clutch Operating Cylinder .......................................25

Revision: August 2007 CL-1 2008 Frontier

 Clutch Disc ............................................................. 25 Clutch Pedal ............................................................ 25
Clutch Cover ........................................................... 25
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Revision: August 2007 CL-2 2008 Frontier

 ProCarManuals.com

Symptom
CLUTCH

Reference page

Revision: August 2007

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

SUSPECTED PARTS (Possible cause)

Clutch does not disengage

NVH Troubleshooting Chart

CLUTCH PEDAL (Free play out of adjustment) CL-7

1
1
CLUTCH LINE (Air in line) CL-8

2
1
SYMPTOM DIAGNOSIS

MASTER CYLINDER PISTON CUP (Damaged) CL-10

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

OPERATING CYLINDER PISTON CUP (Damaged) CL-12

4
2
EM-73 (QR25DE),
ENGINE MOUNTING (Loose)

1
EM-214 (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-86 (QR25DE),
FLYWHEEL (Distortion)
5

2008 Frontier
EM-229 (VQ40DE)
INFOID:0000000003297069

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:0000000003297070

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-
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ness connectors.
Precaution for Procedure without Cowl Top Cover INFOID:0000000003297071

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

PIIB3706J

Service Notice or Precautions INFOID:0000000003297072

•Always use recommended fluid. Refer to MA-12, "Fluids and Lubricants".

•Never reuse drained fluid.
•Be careful not to splash fluid on painted areas.
•When removing and installing clutch piping, use tool.
•Use new fluid to clean or wash all parts of master cylinder.
•Never use mineral oils such as gasoline or kerosene. It will ruin the
rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not
use compressed air.

SBR686C

Revision: August 2007 CL-4 2008 Frontier

 PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000003297073
B

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

ZZA0508D

F
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.
G
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H
ZZA1178D

Commercial Service Tool INFOID:0000000003297074

Tool name Description

Pin punch Removing and installing master cylinder J
spring pin
Tip diameter: 4.5 mm (0.177 in) dia.

ZZA0515D L
Power tool Loosening bolts and nuts

N
PBIC0190E

1. Flare nut crowfoot Removing and installing clutch piping

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

S-NT360

Revision: August 2007 CL-5 2008 Frontier

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

NT077

Bearing drift Installing release bearing

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

NT474
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Revision: August 2007 CL-6 2008 Frontier

 CLUTCH PEDAL
< ON-VEHICLE MAINTENANCE >
ON-VEHICLE MAINTENANCE A
CLUTCH PEDAL
On-Vehicle Inspection and Adjustment INFOID:0000000003297075
B

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.
C
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. CL
b. Tighten the lock nut to the specified torque. Refer to CL-9,
"Exploded View".
c. Verify that the clevis pin floats in the bore of the clutch pedal. It E
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. F
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.
G
b. If any sticking is noted, replace the assembly.
3. Adjust clearance “C” while depressing clutch pedal fully. (With
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clutch interlock switch)

H
Clearance "C" : 0.1 - 1.0 mm (0.004 - 0.039 in)
4. Check clutch hydraulic and system components (clutch master I
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 J
necessary.
b. If hydraulic system repair was necessary, bleed the clutch
hydraulic system. Refer to CL-8, "Bleeding".
NOTE: K
Do not use a vacuum assist or any other type of power bleeder
on this system. Use of a vacuum assist or power bleeder will not
purge all the air from the system. L

SCL800 N

Revision: August 2007 CL-7 2008 Frontier

 CLUTCH FLUID
< ON-VEHICLE MAINTENANCE >
CLUTCH FLUID
Bleeding INFOID:0000000003297076

CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected
area with water.
NOTE:
• Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all the air from the system.
• Monitor the fluid level in the reservoir tank to make sure it does not empty.
1. Top off reservoir with new recommended brake fluid. Refer to MA-12, "Fluids and Lubricants".
2. Connect a transparent vinyl tube and container to the air bleeder
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
release the air.
5. Close the bleeder valve.
6. Repeat steps 3 to 5 until clear brake fluid comes out of the air
bleeder valve.
7. Tighten the air bleeder to the specified torque. Refer to CL-12,
"Exploded View". SCL203-A
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Revision: August 2007 CL-8 2008 Frontier

 CLUTCH PEDAL
< ON-VEHICLE REPAIR >
ON-VEHICLE REPAIR A
CLUTCH PEDAL
Exploded View INFOID:0000000003297077
B

CL

G
ProCarManuals.com

WCIA0548E
H
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) I
10. Clevis pin

Removal and Installation INFOID:0000000003297078

J

REMOVAL
1. Remove the clutch pedal bracket nuts from inside the engine compartment. K
2. Disconnect the clutch interlock switch and ASCD clutch switch, then remove the wiring harness from the
pedal assembly.
3. Remove the snap pin and clevis pin. L
4. Remove the pedal bracket bolt and then remove the clutch pedal assembly.
INSTALLATION
M
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. N

Inspection INFOID:0000000003297079

O
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.
P

Revision: August 2007 CL-9 2008 Frontier

 CLUTCH MASTER CYLINDER
< ON-VEHICLE REPAIR >
CLUTCH MASTER CYLINDER
Exploded View INFOID:0000000003297080

WCIA0438E
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1. Nipple 2. Clamp 3. Reservoir hose

4. Cylinder body 5. Clutch tube 6. Dust cover
7. Clevis 8. Clevis pin 9. Snap pin
10. Stopper ring 11. Stopper 12. Push rod
13. Piston assembly 14. Return spring 15. Reservoir seal
16. Spring pin

Removal and Installation INFOID:0000000003297081

REMOVAL
1. Remove the snap pin and clevis pin from the clevis, and separate it from the clutch pedal.
2. Drain the brake fluid from the clutch hydraulic system.
CAUTION:
Do not spill brake fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
3. Remove the hose clamp and hose from the clutch master cylinder.
4. Remove the clutch tube using suitable tool.
5. Remove the clutch master cylinder nuts, and remove the clutch master cylinder from the vehicle.
INSTALLATION
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
push rod.

Length “L”
QR25DE : 119.5 mm (4.70 in)
VQ40DE : 120.5 mm (4.74 in)
• After installation, inspect and adjust the clutch pedal as necessary,
then bleed the clutch hydraulic system. Refer to CL-7, "On-Vehicle
Inspection and Adjustment" and CL-8, "Bleeding". SCIA5158E

Revision: August 2007 CL-10 2008 Frontier

 CLUTCH MASTER CYLINDER
< ON-VEHICLE REPAIR >
Disassembly and Assembly INFOID:0000000003297082

A
DISASSEMBLY
1. Remove the spring pin, using suitable tool.
B
2. Remove the nipple and reservoir seal from the cylinder body.
3. Loosen the push rod lock nut then remove the clevis and lock
nut, if necessary.
NOTE: C
Clutch pedal height is controlled with the position of the clevis
and push rod.
4. Remove the dust cover from the cylinder body. CL
5. Remove the stopper ring and stopper. Remove the push rod
from the cylinder body while holding it securely to prevent the WCIA0496E
piston assembly from popping out. E
6. Remove the piston assembly and return spring.
ASSEMBLY
F
1. Apply rubber lubricant to the internal surface of the cylinder body, sliding surface of piston assembly, and
the piston cup. Insert the return spring and piston assembly to the cylinder body.
2. Apply silicone grease to the push rod and install the stopper and stopper ring.
G
CAUTION:
Restrain the push rod while doing this because there is a danger the piston assembly will fly out
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of the master cylinder.

3. Install the dust cover to the cylinder body. H
4. Install the reservoir seal and nipple to the cylinder body.
5. Install the clevis to the push rod.
I
6. Check and adjust the position of the clevis and push rod. After
adjusting the length "L", tighten lock nut to the specified torque.
Refer to CL-10, "Exploded View".
J
Length “L”
QR25DE : 119.5 mm (4.70 in)
K
VQ40DE : 120.5 mm (4.74 in)

L
SCIA5158E

Inspection INFOID:0000000003297083
M
INSPECTION AFTER DISASSEMBLY
Inspect for the following, replace parts as necessary.
• Damage, foreign material, wear, corrosion, and pin holes on the cylinder inner surface N
• Damaged or deformed nipple
• Weak spring
• Cracked or deformed dust cover O

Revision: August 2007 CL-11 2008 Frontier

 OPERATING CYLINDER
< ON-VEHICLE REPAIR >
OPERATING CYLINDER
Exploded View INFOID:0000000003297084

WCIA0439E
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1. Dust cover 2. Push rod 3. Piston

4. Piston cup 5. Piston spring 6. Air bleeder
7. Clutch hose 8. Copper washer 9. Cylinder body

Removal and Installation INFOID:0000000003297085

REMOVAL
1. Drain the brake fluid from the clutch hydraulic system.
CAUTION:
Do not spill brake fluid on painted surfaces. If it spills, wipe up immediately and wash the affected
area with water.
2. Remove the clutch hose and copper washer from the operating cylinder.
CAUTION:
Do not reuse the copper washer.
3. Remove the operating cylinder bolts, and remove the operating cylinder from the vehicle.
INSTALLATION
Installation is in the reverse order of removal.
• Tighten the clutch hose fitting to the specified torque. Refer to CL-14, "Exploded View".
CAUTION:
Make sure the clutch hose is not bent or twisted.
• After installation, bleed the clutch hydraulic system. Refer to CL-8, "Bleeding".
Disassembly and Assembly INFOID:0000000003297086

DISASSEMBLY
• Remove the dust cover, push rod and piston assembly from the cylinder body.
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.
3. Apply rubber grease to the dust cover and install the push rod and dust cover.

Revision: August 2007 CL-12 2008 Frontier

 OPERATING CYLINDER
< ON-VEHICLE REPAIR >
Inspection INFOID:0000000003297087

A
INSPECTION AFTER DISASSEMBLY
Inspect for the following, replace parts as necessary.
• Damage, foreign material, wear, corrosion, and pinholes on the cylinder inner surface, piston, and sliding B
part of piston cup
• Weak spring
• Cracked or deformed dust cover C

CL

G
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Revision: August 2007 CL-13 2008 Frontier

 CLUTCH PIPING
< ON-VEHICLE REPAIR >
CLUTCH PIPING
Exploded View INFOID:0000000003297088

WCIA0440E

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:0000000003297089

Carefully observe the following during clutch tube removal and installation.
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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-8, "Bleeding".

Revision: August 2007 CL-14 2008 Frontier

 CLUTCH RELEASE MECHANISM
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION A
CLUTCH RELEASE MECHANISM
5M/T
B
5M/T : Exploded View INFOID:0000000003297120

CL

G
ProCarManuals.com

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:0000000003297121

J
REMOVAL
1. Remove the manual transmission from the vehicle. Refer to TM-19, "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: August 2007 CL-15 2008 Frontier

 CLUTCH RELEASE MECHANISM
< 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.
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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:0000000003297122

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: August 2007 CL-16 2008 Frontier

 CLUTCH RELEASE MECHANISM
< REMOVAL AND INSTALLATION >
6M/T : Exploded View INFOID:0000000003297090

CL

LCIA0373E

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

6M/T : Removal and Installation INFOID:0000000003297091

H

REMOVAL
1. Remove the manual transmission from the vehicle. Refer to TM-75, "Removal and Installation from Vehi- I
cle (For 2WD Models)" or TM-77, "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: August 2007 CL-17 2008 Frontier

 CLUTCH RELEASE MECHANISM
< 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.
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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 transaxle 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:0000000003297092

INSPECTION AFTER REMOVAL

Revision: August 2007 CL-18 2008 Frontier

 CLUTCH RELEASE MECHANISM
< 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

G
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Revision: August 2007 CL-19 2008 Frontier

 CLUTCH DISC, CLUTCH COVER
< REMOVAL AND INSTALLATION >
CLUTCH DISC, CLUTCH COVER
5M/T
5M/T : Exploded View INFOID:0000000003297124
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ALDIA0016ZZ

1. Flywheel 2. Clutch disc 3. Clutch cover

A. First step B. Final Step

5M/T : Removal and Installation INFOID:0000000003297125

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-19, "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: August 2007 CL-20 2008 Frontier

 CLUTCH DISC, CLUTCH COVER
< 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
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3. Install the manual transmission. Refer to TM-19, "Removal and Installation from Vehicle".
H
5M/T : Inspection and Adjustment INFOID:0000000003297156

INSPECTION AND ADJUSTMENT 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

Revision: August 2007 CL-21 2008 Frontier

 CLUTCH DISC, CLUTCH COVER
< REMOVAL AND 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 ( — )

• Check clutch cover thrust ring for wear or damage. If wear or dam-
age is found, replace clutch cover assembly. PCIB0276E
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-86, "Inspection After Dis-
assembly".
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PBIC2168E

6M/T
6M/T : Exploded View INFOID:0000000003297093

WCIA0522E

1. Flywheel 2. Clutch disc 3. Clutch cover

6M/T : Removal and Installation INFOID:0000000003297094

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.

Revision: August 2007 CL-22 2008 Frontier

 CLUTCH DISC, CLUTCH COVER
< REMOVAL AND INSTALLATION >
• If the flywheel is removed, align the dowel pin with the smallest hole of flywheel. Refer to EM-219,
"Disassembly and Assembly". A
REMOVAL
1. Remove the manual transmission from the vehicle. Refer to TM-75, "Removal and Installation from Vehi-
cle (For 2WD Models)" or TM-77, "Removal and Installation from Vehicle (For 4WD Models)". B
2. Remove the clutch cover bolts using power tool. Remove the clutch cover and clutch disc.
INSTALLATION C
1. Apply recommended grease to clutch disc and main drive shaft spline.
CAUTION:
Do not allow grease to contaminate the clutch facing. CL
2. Install clutch disc and clutch cover. Pre-tighten the bolts and
install Tool. Then tighten the clutch cover bolts evenly in two
steps to the specified torque in the order shown. Refer to CL-22, E
"6M/T : Exploded View".

Tool number : ST20630000 (J-26366)

F

G
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LCIA0391E
K
3. Install the manual transmission. Refer to TM-75, "Removal and Installation from Vehicle (For 2WD Mod-
els)" or TM-77, "Removal and Installation from Vehicle (For 4WD Models)".
6M/T : Inspection and Adjustment INFOID:0000000003297095
L

INSPECTION AND ADJUSTMENT AFTER REMOVAL

M
Clutch Disc
• Check the wear of the clutch disc facing.
N
Clutch disc facing : Refer to CL-25, "Clutch Disc".
wear

SCL229

Revision: August 2007 CL-23 2008 Frontier

 CLUTCH DISC, CLUTCH COVER
< 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
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 ( — )

• Check clutch cover thrust ring for wear or damage. If wear or dam-
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age is found, replace clutch cover assembly. PCIB0276E

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-229, "Inspection After Dis-
assembly".

PBIC2168E

Revision: August 2007 CL-24 2008 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:0000000003297160
B

Type of clutch control Hydraulic

C
Clutch Master Cylinder INFOID:0000000003297161

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

Clutch Operating Cylinder INFOID:0000000003297162

E
Unit: mm (in)

Inner diameter 19.05 (3/4)

F
Clutch Disc INFOID:0000000003297163

Unit: mm (in) G
Engine model QR25DE VQ40DE
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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:0000000003297164

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
Clutch Pedal INFOID:0000000003297165

Unit: mm (in)
N
Clearance ″C″ between pedal stopper rubber and clutch interlock switch
0.1 - 1.0 (0.004 - 0.039)
threaded while clutch pedal is fully depressed.

Revision: August 2007 CL-25 2008 Frontier