CLUTCH

C TRANSMISSION/TRANSAXLE

SECTION CL CLUTCH
B

CL

E
CONTENTS
PRECAUTIONS .......................................................... 2 INSTALLATION ................................................... 11 F
Precautions for Battery Service ................................ 2 Disassembly and Assembly .................................... 11
Caution ..................................................................... 2 DISASSEMBLY ................................................... 11
PREPARATION ........................................................... 3 INSPECTION AFTER DISASSEMBLY ................ 11 G
Special Service Tools ............................................... 3 ASSEMBLY ......................................................... 11
Commercial Service Tools ........................................ 3 CLUTCH PIPING ....................................................... 12
NOISE, VIBRATION AND HARSHNESS (NVH) Removal and Installation ........................................ 12
H
TROUBLESHOOTING ................................................ 4 CLUTCH RELEASE MECHANISM ........................... 13
NVH Troubleshooting Chart ..................................... 4 Removal and Installation ........................................ 13
CLUTCH PEDAL ........................................................ 5 REMOVAL ........................................................... 13
On-Vehicle Inspection and Adjustment .................... 5 INSPECTION AFTER REMOVAL ....................... 13 I
Removal and Installation .......................................... 6 INSTALLATION ................................................... 14
REMOVAL ............................................................. 6 CLUTCH DISC, CLUTCH COVER ............................ 15
INSPECTION AFTER REMOVAL ......................... 6 Removal and Installation (M/T Model Code Num- J
INSTALLATION ..................................................... 6 ber: CD008) ............................................................ 15
CLUTCH FLUID .......................................................... 7 REMOVAL ........................................................... 15
Bleeding ................................................................... 7 INSPECTION AND ADJUSTMENT AFTER
K
CLUTCH MASTER CYLINDER .................................. 8 REMOVAL ........................................................... 15
Removal and Installation .......................................... 8 INSTALLATION ................................................... 16
REMOVAL ............................................................. 8 Removal and Installation (M/T Model Code Num-
INSTALLATION ..................................................... 9 ber: CD009) ............................................................ 17 L
Disassembly and Assembly ..................................... 9 REMOVAL ........................................................... 17
DISASSEMBLY ..................................................... 9 INSPECTION AND ADJUSTMENT AFTER
INSPECTION AFTER DISASSEMBLY ............... 10 REMOVAL ........................................................... 17 M
ASSEMBLY ......................................................... 10 INSTALLATION ................................................... 18
OPERATING CYLINDER ...........................................11 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 19
Removal and Installation .........................................11 Clutch Control System ............................................ 19
REMOVAL ............................................................11 Clutch Master Cylinder ........................................... 19
Clutch Operating Cylinder ...................................... 19
Clutch Disc ............................................................. 19
Clutch Cover ........................................................... 19
Clutch Pedal ........................................................... 19

Revision: 2004 December CL-1 2005 350Z

 PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions for Battery Service ACS006FW

Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interfer-
ence between the window edge and the vehicle when the door is opened/closed. During normal operation, the
window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic
window function will not work with the battery disconnected.
Caution ACS004MV

● Recommended fluid is brake fluid “DOT 3”. Refer to MA-12, "RECOMMENDED FLUIDS AND
LUBRICANTS" .
● Never reuse drained brake fluid.
● Be careful not to splash brake fluid on painted areas.
● When removing and installing clutch piping, use Tool.
● Use new brake fluid to clean or wash all parts of master cyl-
inder and operating 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: 2004 December CL-2 2005 350Z

 PREPARATION

PREPARATION PFP:00002
A
Special Service Tools ACS004MW

The actual shapes of Kent-Moore tool may differ from those of special service tools illustrated here.
Tool number B
(Kent-Moore No.) Description
Tool name

KV30101400 Installing release bearing

CL
( — )
Drift
a: 51 mm (2.01 in) dia.
b: 44 mm (1.73 in) dia. D

ZZA0838D

ST20050240 Adjusting unevenness of diaphragm spring of

E
( — ) clutch cover
Diaphragm adjusting wrench
F

ZZA0508D
G
ST20670000 Installing clutch disc
( — )
Clutch aligning bar
H
a: 15 mm (0.59 in) dia.
b: 23 mm (0.91 in) dia.

I
ZZA1178D

Commercial Service Tools ACS004MX

J
Tool name Description

Pin punch Removing and installing master cylinder

Tip diameter: 4.5 mm (0.177 in) dia. spring pin K

ZZA0515D

1. Flare nut crowfoot Removing and installing clutch piping M

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

S-NT360

Power tool Loosening bolts and nuts

PBIC0190E

Revision: 2004 December CL-3 2005 350Z

 page

Symptom
Reference

CD009
CD008

Clutch slips

Revision: 2004 December

Clutch noisy
Clutch pedal spongy
Clutch grabs/chatters
SUSPECTED PARTS (Possible cause)
M/T model code number:
M/T model code number:

Clutch does not disengage

NVH Troubleshooting Chart

CLUTCH PEDAL (Free play out of adjustment) CL-5

1
1
CLUTCH LINE (Air in line) CL-7

2
1
tion. If necessary, repair or replace these parts.

MASTER CYLINDER PISTON CUP (Damaged) CL-9

3
2
OPERATING CYLINDER PISTON CUP (Damaged) CL-11

4
2
ENGINE MOUNTING (Loose) EM-131

CL-4
RELEASE BEARING (Worn, dirty or damaged) CL-13

1
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
CLUTCH DISC (Worn out) CL-17 CL-15

2
2

CLUTCH DISC (Hardened)

2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

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

PRESSURE PLATE (Distortion)

7
4

FLYWHEEL (Distortion) EM-166

5
PFP:00003

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

2005 350Z
ACS004MY
 CLUTCH PEDAL

CLUTCH PEDAL PFP:46540

A
On-Vehicle Inspection and Adjustment ACS004MZ

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. B
a. If the clevis pin is not free, check that the ASCD clutch switch is
not applying pressure to the clutch pedal causing the clevis pin
to bind. To adjust, loosen lock nut and turn ASCD clutch switch.
CL
b. Tighten the lock nut.
c. Verify that the clevis pin floats in the bore of the clutch pedal. It
should not be bound by the clutch pedal. D
d. If the clevis pin is still not free, remove the clevis pin and check
for deformation or damage. Replace clevis pin if necessary. PCIB0758E
Leave pin removed for step 2.
E
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 related parts (clutch pedal bracket, assist spring, bushing etc.). Re- F
assemble the clutch pedal and re-verify that the clevis pin floats freely in the bore of the clutch pedal.
3. Adjust clearance “C” while depressing clutch pedal fully. (With
clutch interlock switch)
G
Clearance C : 0.1 - 1.0mm (0.004 - 0.039 in)
4. Check clutch hydraulic and system components (clutch master
cylinder, clutch operating cylinder, clutch withdrawal lever, clutch H
release bearing, etc.) for sticking or binding.
a. If any sticking or binding noted, repair or replace related parts as
necessary. I
b. If hydraulic system repair was necessary, bleed the clutch
hydraulic system. Refer to CL-7, "Bleeding" .
NOTE: J
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. K

PCIB0757E
M

Revision: 2004 December CL-5 2005 350Z

 CLUTCH PEDAL

Removal and Installation ACS004N0

PCIB0864E

1. Clutch interlock switch 2. Bracket 3. Clevis pin

4. Pedal stopper rubber 5. Clutch pedal 6. Stopper rubber
7. Pedal pad 8. ASCD clutch switch 9. Bushing
10. Snap pin

REMOVAL
1. Remove kicking plate. Refer to EI-35, "Removal and Installation (for Coupe Models)" or EI-37, "Removal
and Installation (for Roadster Models)" .
2. Remove footrest. Refer to EI-43, "Removal and Installation" .
3. Remove dash side finisher (LH). Refer to IP-11, "Removal and Installation" .
4. Remove instrument driver panel lower. Refer to IP-11, "Removal and Installation" .
5. Remove VDC/TCS/ABS control unit. (VDC/TCS/ABS models) Refer to BRC-145, "Removal and Installa-
tion" .
6. Remove the clutch interlock switch and ASCD clutch switch connectors and harness.
7. Remove the snap pin and clevis pin.
8. Remove the pedal bracket mounting bolt and nuts and then remove the clutch pedal assembly.
INSPECTION AFTER REMOVAL
● Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace the clutch pedal assembly.
INSTALLATION
To install, reverse the removal procedure, following the cautions below:
● Install clutch pedal assembly and adjust the pedal height. Tighten ASCD clutch switch lock nut to the
specified torque.
● After installing the clutch interlock switch, adjust the switch position.
NOTE:
Tighten the ASCD clutch switch lock nut to the specified torque after installing the clutch pedal assembly in the
vehicle and adjusting the pedal free play.

Revision: 2004 December CL-6 2005 350Z

 CLUTCH FLUID

CLUTCH FLUID PFP:00017

A
Bleeding ACS004N1

CAUTION:
● Monitor fluid level in the reservoir tank to make sure it does not empty. B
● Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
NOTE: CL
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.
1. Fill the master cylinder reservoir tank with new clutch fluid. D
2. Connect a transparent vinyl hose to the air bleeder.
3. Depress the clutch pedal quickly and fully a few times and hold
it. E
4. With clutch pedal depressed, open air bleeder to release air.
5. Close air bleeder.
6. Release clutch pedal and wait for 5 seconds. F
7. Repeat steps 3 to 6 until no bubbles can be observed in the
brake fluid.
8. Tighten air bleeder to the specified torque. Refer to CL-11, SCIA1496E
G
"Removal and Installation" .

Revision: 2004 December CL-7 2005 350Z

 CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER PFP:30610

Removal and Installation ACS004N2

PCIB0759E

1. Nipple 2. Clamp 3. Reservoir hose

4. Cylinder body 5. Packing 6. Seat
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
1. Remove kicking plate. Refer to EI-35, "Removal and Installation (for Coupe Models)" or EI-37, "Removal
and Installation (for Roadster Models)" .
2. Remove footrest. Refer to EI-43, "Removal and Installation" .
3. Remove dash side finisher. Refer to IP-11, "Removal and Installation" .
4. Remove instrument driver panel lower. Refer to IP-11, "Removal and Installation" .
5. Remove VDC/TCS/ABS control unit. (VDC/TCS/ABS models) Refer to BRC-145, "Removal and Installa-
tion" .
6. Remove snap pin and clevis pin from the clevis, and separate it from clutch pedal.
7. Remove hoodledge cover.
8. Drain clutch fluid in reservoir tank and remove reservoir hose.
CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
9. Remove reservoir tank.
10. Remove clutch tube using a flare nut wrench. Refer to CL-12,
"Removal and Installation" .
11. Remove master cylinder assembly.

SCIA1587E

Revision: 2004 December CL-8 2005 350Z

 CLUTCH MASTER CYLINDER

INSTALLATION
1. Connect clutch tube to master cylinder assembly and temporarily tighten flare nut. A
2. Install master cylinder assembly and tighten mounting nuts to the specified torque.
3. Tighten clutch tube flare nut to the specified torque using a flare nut torque wrench. Refer to CL-12,
"Removal and Installation" . B
4. Install clevis to the clutch pedal, and fix clevis with clevis pin.
5. Install snap pin to the clevis pin.
CL
6. Install reservoir hose to the nipple. Install the reservoir tank to
the vehicle, and then tighten mounting nuts to the specified
torque.
D
: 5.8 N·m (0.59 Kg-m, 51 in-lb)
7. After completing this procedure, inspect and adjust for clutch
pedal and then bleed the clutch hydraulic system. Refer to CL-5, E
"On-Vehicle Inspection and Adjustment" and CL-7, "Bleeding" .
8. Install hoodledge cover.
9. Install VDC/TCS/ABS control unit. (VDC/TCS/ABS models) F
SCIA1587E
Refer to BRC-145, "Removal and Installation" .
10. Install instrument driver panel lower. Refer to IP-11, "Removal and Installation" .
11. Install dash side finisher. Refer to IP-11, "Removal and Installation" . G
12. Install footrest.Refer to EI-43, "FLOOR TRIM" .
13. Install kicking plate. Refer to EI-35, "Removal and Installation (for Coupe Models)" or EI-37, "Removal
H
and Installation (for Roadster Models)" .
Disassembly and Assembly ACS004N3

DISASSEMBLY I
1. Remove spring pin, nipple and reservoir seal from cylinder body
using a pin punch.
2. Loosen push rod lock nut. Remove clevis and lock nut. J
3. Remove the seat from the cylinder body.
4. Remove the stopper ring and stopper, and then remove the
push rod, piston assembly and return spring from the cylinder K
body.
CAUTION:
Restrain the push rod while doing this because there is a L
danger the piston assembly will fly out of the cylinder body. PCIB0274E

Revision: 2004 December CL-9 2005 350Z

 CLUTCH MASTER CYLINDER

INSPECTION AFTER DISASSEMBLY

Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.
● Damaged cylinder internal wall, foreign matter, wear, corrosion, or pin hole
● Damaged or deformed nipple or reservoir tank
● Settling of the spring
● Cracked and deformed seat
ASSEMBLY
1. Apply rubber lubricant to internal surface of the cylinder body, sliding surface of piston assembly, and the
piston cup. Insert return spring and piston assembly to the cylinder body.
2. Apply silicone grease to the push rod and install the stopper before installing the stopper ring.
CAUTION:
Restrain the push rod while doing this because there is a danger the piston assembly will fly out
of the master cylinder.
3. Install seat to the cylinder body.
4. Install clevis to the push rod and tighten lock nut to the specified torque. Refer to CL-8, "Removal and
Installation" .
5. Install reservoir seal and nipple to cylinder body. Install spring pin using a pin punch.

Revision: 2004 December CL-10 2005 350Z

 OPERATING CYLINDER

OPERATING CYLINDER PFP:30620

A
Removal and Installation ACS004N4

CL

G
PCIB0863E

1. Air bleeder 2. Clutch hose 3. Union bolt

4. Copper washer 5. Cylinder body 6. Dust cover H
7. Push rod 8. Piston 9. Piston cup
10. Piston spring

REMOVAL I
1. Drain clutch fluid.
CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the J
affected area with water.
2. Remove clutch hose from the operating cylinder.
3. Remove operating cylinder mounting bolts and then remove operating cylinder from the vehicle. K

INSTALLATION
To install, reverse the removal procedure, following the cautions below: L
● Install hose with care so that it will not be bent or twisted. Refer to CL-12, "Removal and Installation" .
● After completing the procedure, bleed the clutch hydraulic system. Refer to CL-7, "Bleeding" .
M
Disassembly and Assembly ACS004N5

DISASSEMBLY
● Remove dust cover and push rod. Remove piston, piston cup, and piston spring from inside the cylinder
body.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.
● Damage to cylinder inner surface or piston sliding surface. Foreign matter, wear, corrosion, or pin hole
● Settling of the spring
● Cracked or deformed dust cover
ASSEMBLY
1. Apply rubber lubricant to cylinder body inner surface and rubber grease to the piston cup and piston.
Insert piston assembly and piston spring into the cylinder body.
2. Apply rubber grease to dust cover and install push rod and dust cover.

Revision: 2004 December CL-11 2005 350Z

 CLUTCH PIPING

CLUTCH PIPING PFP:30650

Removal and Installation ACS004N6

M/T model code number: CD008

PCIB1391E

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

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

M/T model code number: CD009

PCIB0813E

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

4. Operating cylinder 5. Clutch pedal 6. Master cylinder

Carefully observe the following steps during clutch tube removal and installation.
● Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected area
with water.
● When fixing clutch hose to bracket, align clutch hose metal fit-
tings with bracket positioning emboss and lock plate to secure.
At this time, prevent twisting or damage of clutch hose. In addi-
tion, be careful not to damage clutch hose.
● Tighten clutch tube flare nut to the specified torque.
CAUTION:
Be careful not to damage flare nut and clutch tube.
● Tighten the union bolt to the specified torque. Refer to CL-11,
"Removal and Installation" .
CAUTION: PCIB0681E
Do not reuse the copper washer.
● After installation, bleed the clutch hydraulic system. Refer to CL-7, "Bleeding" .

Revision: 2004 December CL-12 2005 350Z

 CLUTCH RELEASE MECHANISM

CLUTCH RELEASE MECHANISM PFP:30502

A
Removal and Installation ACS004N7

CL

G
PCIB0810E

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

4. Withdrawal lever 5. Dust cover 6. Snap spring H
REMOVAL
1. Remove manual transmission from the vehicle. Refer to MT-18, "Removal and Installation from Vehicle" .
2. Remove release bearing sleeve assembly, holder spring and withdrawal lever from inside the clutch hous- I
ing.
3. Remove dust cover.
J
4. Remove snap spring from withdrawal lever.
5. Remove release bearing from release bearing sleeve using a
puller.
K

CLA0013D

INSPECTION AFTER REMOVAL

● If release bearing is seized, damaged, not properly centered or
does not rotate smoothly, replace it.
● If contact surface of withdrawal lever is excessively worn out,
replace it.
● If dust cover is cracked or deformed, replace it.

SCIA1660E

Revision: 2004 December CL-13 2005 350Z

 CLUTCH RELEASE MECHANISM

INSTALLATION
CAUTION:
● Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or quiver. Wipe off any grease oozing
from the parts.
● Be careful not to bring any grease into contact with the clutch disc facing, pressure plate surface
and flywheel surface.
1. Install release bearing to release bearing sleeve using the drift.
Tool number : KV30101400 ( — )
CAUTION:
Press bearing inner race by pushing with the drift.

PCIB0275E

2. Following the instructions below, apply grease to the specified points.

SCIA6798E

CAUTION:
Wipe off any old grease, debris, or powdery residue left on the surfaces.
● Evenly apply a 1 mm (0.04 in) thick coating of recommended grease to withdrawal lever and release
bearing sleeve or holder spring sliding surface.
● Apply recommended grease to ball pin contact surface of withdrawal lever and inner slots of release
bearing. The grease surface should be level with the surrounding area.
● Evenly apply a thin coat of recommended grease to release bearing sliding surface. Install release
bearing. Wipe off any excess grease that oozes from the parts and then remove release bearing.
3. To install, reverse the removal procedure, following the cautions below.
CAUTION:
● Before installing manual transmission to the vehicle, check that each sliding surface slides
smoothly by operating withdrawal lever.
● When assembling, make sure that both ends of snap
spring touch the end face of withdrawal lever.
● Be careful with the orientation of installation.

PCIB0837E

Revision: 2004 December CL-14 2005 350Z

 CLUTCH DISC, CLUTCH COVER

CLUTCH DISC, CLUTCH COVER PFP:30100

A
Removal and Installation (M/T Model Code Number: CD008) ACS004N8

CL

G
PCIB1372E

1. Flywheel 2. Clutch disc 3. Clutch cover

CAUTION: H
● Be careful not to bring any grease into contact with the clutch disc facing, pressure plate surface
and flywheel surface.
● If flywheel is removed, align dowel pin with the smallest hole of flywheel. Refer to EM-144, I
"ASSEMBLY" .
REMOVAL
1. Remove manual transmission from the vehicle. Refer to MT-18, "Removal and Installation from Vehicle" . J
2. Loosen clutch cover mounting bolts with power tool. Remove clutch cover and clutch disc.
INSPECTION AND ADJUSTMENT AFTER REMOVAL K
Clutch Disc
● Measure circumference runout relative to the clutch disc center
spline. If it is outside the specification, replace the clutch disc. L
Runout limit/diameter of the area to be measured
:0.7 mm (0.028 in) or less/240 mm (9.45 in) dia.
M
● Measure backlash for clutch disc spline and main drive shaft
spline at the circumference of the disc. If it is outside the speci-
fied range, replace the clutch disc.
Maximum backlash of spline
:1.0 mm (0.039 in) SCL221

● Measure the depth to clutch disc facing rivet heads using cali-
pers. If it exceeds the allowable wear limit, replace the clutch
disc.
Facing wear limit (depth to the rivet head)
:0.3 mm (0.012 in)

SCL229

Revision: 2004 December CL-15 2005 350Z

 CLUTCH DISC, CLUTCH COVER

Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using the diaphragm adjusting wrench.
Tolerance for diaphragm spring lever unevenness
:0.5mm (0.020 in)

Tool number : ST20050240 ( — )

● Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover assembly.
NOTE: PCIB0276E
● 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 sandpaper. If surface is damaged or distorted, replace the assembly.
INSTALLATION
1. Apply recommended grease to clutch disc and main drive shaft spline.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or quiver. Wipe off any grease oozing
from the parts.
2. Install clutch disc and clutch cover. Pre-tighten mounting bolts
and install clutch aligning bar.
Tool number :ST20670000 ( — )
3. Tighten clutch cover mounting bolts evenly in two steps in the
order shown in the figure. Refer to CL-15, "Removal and Instal-
lation (M/T Model Code Number: CD008)" .
4. Install manual transmission. Refer to MT-18, "Removal and
Installation from Vehicle" .

PCIB0277E

Revision: 2004 December CL-16 2005 350Z

 CLUTCH DISC, CLUTCH COVER

Removal and Installation (M/T Model Code Number: CD009) ACS00A28

CL

PCIB1338E

1. Flywheel 2. Clutch disc 3. Clutch cover G

CAUTION:
● Be careful not to bring any grease into contact with the clutch disc facing, pressure plate surface
H
and flywheel surface.
● If flywheel is removed, align dowel pin with the smallest hole of flywheel. Refer to EM-144,
"ASSEMBLY" .
I
● Replace clutch disc and clutch cover as a set.
REMOVAL
1. Remove manual transmission from the vehicle. Refer to MT-18, "Removal and Installation from Vehicle" . J
2. Loosen clutch cover mounting bolts with power tool. Remove clutch cover and clutch disc.
INSPECTION AND ADJUSTMENT AFTER REMOVAL
K
Clutch Disc
● Measure circumference runout relative to the clutch disc center
spline. If it is outside the specification, replace clutch disc and
clutch cover as a set. L

Runout limit/diameter of the area to be measured

:1.0 mm (0.039 in) or less/230 mm (9.06 in) dia. M
● Measure backlash for clutch disc spline and main drive shaft
spline at the circumference of the clutch disc. If it is outside the
specified range, replace clutch disc and clutch cover as a set.
Maximum backlash of spline
SCL221

:1.0 mm (0.039 in)

Revision: 2004 December CL-17 2005 350Z

 CLUTCH DISC, CLUTCH COVER

● Using calipers, measure the depth to the clutch disc facing rivet
heads. If it exceeds the allowable wear limit, replace clutch disc
and clutch cover as a set.
Facing wear limit (depth to the rivet head)
:0.3 mm (0.012 in)

SCL229

Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using the diaphragm adjusting wrench.
Tolerance for diaphragm spring lever unevenness
:0.8 mm (0.031 in)

Tool number : ST20050240 ( — )

● Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch disc and clutch cover as a set.
NOTE: SCIA6796E
● 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 sandpaper. If surface is damaged or distorted, replace clutch disc and clutch cover
as a set.
INSTALLATION
1. Apply recommended grease to clutch disc and main drive shaft spline.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or quiver. Wipe off any grease oozing
from the parts.
2. Install clutch disc and clutch cover. Pre-tighten mounting bolts
and install clutch aligning bar.
Tool number :ST20670000 ( — )
3. Tighten clutch cover mounting bolts evenly in two steps in the
order shown in the figure. Refer to CL-17, "Removal and Instal-
lation (M/T Model Code Number: CD009)" .
4. Install manual transmission. Refer to MT-18, "Removal and
Installation from Vehicle" .

SCIA6797E

Revision: 2004 December CL-18 2005 350Z

 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
Clutch Control System ACS004N9

Type of clutch control Hydraulic

B
Clutch Master Cylinder ACS004NA

Unit: mm (in)
Inner diameter 15.87 (5/8) CL
Clutch Operating Cylinder ACS004NB

Unit: mm (in)
D
Inner diameter 19.05 (3/4)

Clutch Disc ACS004NC

Unit: mm (in) E
Engine model VQ35DE
M/T model code number CD008 CD009
F
Model 250 240
Facing size (Outer dia. × inner dia. × thickness) 250 × 170 × 3.2 (9.84 × 6.69 × 0.126) 240 × 160 × 3.8 (9.45 × 6.30 × 0.150)
Wear limit (depth to the rivet head) 0.3 (0.012) G
Runout limit/diameter of the area to be measured 0.7 (0.028) or less/240 (9.45) dia. 1.0 (0.039) or less/230 (9.06) dia.
Maximum backlash of spline (at outer edge disc) 1.0 (0.039)
H
Clutch Cover ACS004ND

Unit: mm (in)
Engine model VQ35DE I
M/T model code number CD008 CD009
Model 250 240
J
Set-load 8,630 N (880 kg) 9,900 N (1,009 kg)
Diaphragm spring lever height 39.5 - 41.5 (1.555 - 1.634) 41.9 - 44.1 (1.650 - 1.736)
Uneven limit of diaphragm spring toe height 0.5 (0.020) 0.8 (0.031) K
Clutch Pedal ACS004NE

Unit: mm (in)
L
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: 2004 December CL-19 2005 350Z

 SERVICE DATA AND SPECIFICATIONS (SDS)

Revision: 2004 December CL-20 2005 350Z