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CLUTCH
SECTION CL
CONTENTS
PRECAUTIONS ...............................................................2 CLUTCH DAMPER ........................................................13
Precautions ..................................................................2 Components...............................................................13
PREPARATION ...............................................................3 Inspection...................................................................13
Special Service Tools ..................................................3 PIPING ...........................................................................14
Commercial Service Tools ...........................................3 Removal.....................................................................14
NOISE, VIBRATION AND HARSHNESS (NVH) Installation..................................................................14
TROUBLESHOOTING .....................................................4 CLUTCH RELEASE MECHANISM ...............................15
NVH Troubleshooting Chart.........................................4 Components...............................................................15
CLUTCH ...................................................................4 Removal.....................................................................15
CLUTCH SYSTEM...........................................................5 Inspection...................................................................15
Components.................................................................5 Installation..................................................................15
Inspection and Adjustment ..........................................6 CLUTCH DISC, CLUTCH COVER AND
ADJUSTING CLUTCH PEDAL ....................................6 FLYWHEEL....................................................................17
AIR BLEEDING PROCEDURE ....................................6 Components...............................................................17
CLUTCH MASTER CYLINDER.......................................8 Inspection and Adjustment ........................................17
Components.................................................................8 CLUTCH DISC.........................................................17
Removal.......................................................................9 CLUTCH COVER .....................................................18
Installation....................................................................9 FLYWHEEL .............................................................18
Disassembly.................................................................9 Installation..................................................................18
Inspection.....................................................................9 SERVICE DATA AND SPECIFICATIONS (SDS) .........19
Assembly ...................................................................10 Clutch Control System...............................................19
OPERATING CYLINDER...............................................11 Clutch Master Cylinder ..............................................19
Components...............................................................11 Clutch Operating Cylinder .........................................19
Removal.....................................................................11 Clutch Damper...........................................................19
Disassembly...............................................................11 Clutch Disc.................................................................19
Inspection...................................................................11 Clutch Cover ..............................................................19
Assembly ...................................................................12 Clutch Pedal ..............................................................20
Installation..................................................................12
PRECAUTIONS
Precautions
Precautions NFCL0001
+ Recommended fluid is brake fluid "DOT 3" or "DOT 4".
Refer to MA-13, "Fluid and Lubricant".
+ 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
cylinder, operating cylinder and clutch damper.
+ Never use mineral oils such as gasoline or kerosene. It will
ruin the rubber parts of the hydraulic system.
SBR686C
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not
use compressed air.
CL-2
PREPARATION
Special Service Tools
Special Service Tools NFCL0002
Tool number
Description
Tool name
ST20630000 Installing clutch cover and clutch disc
Clutch aligning bar a: 15.8 mm (0.622 in) dia.
b: 22.9 mm (0.902 in) dia.
c: 45.0 mm (1.772 in)
NT405
ST20050240 Adjusting unevenness of diaphragm spring of
Diaphragm spring clutch cover
adjusting wrench a: 150 mm (5.91 in)
b: 25 mm (0.98 in)
NT404
Commercial Service Tools NFCL0003
Tool name Description
1 Flare nut crowfoot Removing and installing clutch piping
2 Torque wrench a: 10 mm (0.39 in)
NT360
CL-3
NVH
Symptom
CLUTCH
Reference page
(Possible cause)
gage
SUSPECTED PARTS
Clutch slips
Clutch noisy
Clutch pedal spongy
Clutch grabs/chatters
Clutch does not disen-
1
1
CLUTCH PEDAL (Free play out of adjustment) CL-6
2
1
CLUTCH LINE (Air in line) CL-6
3
2
MASTER CYLINDER PISTON CUP (Damaged) CL-8
4
2
OPERATING CYLINDER PISTON CUP (Damaged) CL-11
tion. If necessary, repair or replace these parts.
1
ENGINE MOUNTING (Loose) Refer to EM-56, "Removal and Installation".
1
RELEASE BEARING (Worn, dirty or damaged) CL-15
CL-4
5
CLUTCH DISC (Out of true) CL-17
5
2
CLUTCH DISC (Runout is excessive) CL-17
5
CLUTCH DISC (Lining broken) CL-17
5
CLUTCH DISC (Dirty or burned) CL-17
5
2
2
CLUTCH DISC (Oily) CL-17
NVH Troubleshooting Chart
2
2
CLUTCH DISC (Worn out) CL-17
2
CLUTCH DISC (Hardened) CL-17
5
CLUTCH DISC (Lack of spline grease) CL-17
6
3
DIAPHRAGM SPRING (Damaged) CL-18
6
2
DIAPHRAGM SPRING (Out of tip alignment) CL-18
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
7
4
PRESSURE PLATE (Distortion) CL-18
5
FLYWHEEL (Distortion) CL-18
NFCL0004S0101
NFCL0004S01
NFCL0004
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
CLUTCH SYSTEM
Components
Components NFCL0005
SCL832-A
1. Pedal bracket 9. Withdrawal lever 16. ASCD clutch switch
2. Clutch master cylinder 10. Release bearing 17. Washer
3. Pedal stopper bolt 11. Clutch hose 18. Clutch hose connector
4. Fulcrum pin 12. Clutch cover 19. Bushing
5. Pin 13. Clutch disc 20. Stopper rubber
6. Clutch pedal 14. Clevis pin 21. Clutch damper
7. Operating cylinder 15. Assist spring 22. Clutch piping connector
8. Air bleeder valve
CL-5
CLUTCH SYSTEM
Inspection and Adjustment
Inspection and Adjustment NFCL0006
ADJUSTING CLUTCH PEDAL NFCL0006S01
Pedal Height NFCL0006S0101
1. Adjust pedal height with ASCD clutch switch or pedal stopper
bolt.
Pedal height "H":
LHD model:
179.5 - 189.5 mm (7.07 - 7.46 in)
RHD model:
193.5 - 203.5 mm (7.62 - 8.01 in)
SCL715-A
2. Adjust pedal free play with master cylinder push rod. Then
tighten lock nut.
Pedal free play "A":
9 - 16 mm (0.35 - 0.63 in)
+ Push or step on clutch pedal until resistance is felt, and check
the distance the pedal moves.
SCL702
AIR BLEEDING PROCEDURE NFCL0006S02
VQ20DE (LHD) Model NFCL0006S0201
1. Bleed air from clutch damper according to the following proce-
dure.
+ Carefully monitor fluid level at master cylinder during air
bleeding operation.
+ Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
a. Top up reservoir of master cylinder with recommended brake
fluid.
b. Connect a transparent vinyl tube to air bleeder valve.
c. Slowly depress clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 sec-
ond intervals.
d. Holding clutch pedal depressed, open air bleeder valve to
release air.
e. Close air bleeder valve.
f. Release clutch pedal and wait at least 5 seconds.
g. Repeat steps c through f above until brake fluid flows from air
bleeder valve without air bubbles.
SCL833
CL-6
CLUTCH SYSTEM
Inspection and Adjustment (Cont'd)
2. Bleed air from clutch operating cylinder according to the above
same procedure.
3. Repeat the above air bleeding procedures 1 and 2 several
times.
Tightening torque of air bleeder valve:
Refer to "Components", CL-5.
VQ20DE (RHD) Model NFCL0006S0202
1. Bleed air from operating cylinder according to the following
procedure.
+ Carefully monitor fluid level at master cylinder during air
bleeding operation.
+ Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
a. Top up reservoir of master cylinder with recommended brake fluid.
b. Connect a transparent vinyl tube to air bleeder valve.
c. Slowly depress clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 sec-
ond intervals.
d. Holding clutch pedal depressed, open air bleeder valve to
release air.
e. Close air bleeder valve.
f. Release clutch pedal and wait at least 5 seconds.
g. Repeat steps c through f above until brake fluid flows from air
bleeder valve without air bubbles.
2. Repeat the above air bleeding procedure several times.
Tightening torque of air bleeder valve:
Refer to "Components", CL-5.
VQ30DE Model NFCL0006S0203
1. Bleed air from clutch piping connector according to the follow-
ing procedure.
+ Carefully monitor fluid level at master cylinder during air
bleeding operation.
+ Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
a. Top up reservoir of master cylinder with recommended brake
fluid.
b. Connect a transparent vinyl tube to air bleeder valve.
c. Slowly depress clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 sec-
ond intervals.
d. Holding clutch pedal depressed, open air bleeder valve to
release air.
e. Close air bleeder valve.
f. Release clutch pedal and wait at least 5 seconds.
g. Repeat steps c through f above until brake fluid flows from air
bleeder valve without air bubbles.
2. Bleed air from clutch operating cylinder according to the above
same procedure.
3. Repeat the above air bleeding procedures 1 and 2 several
times.
Tightening torque of air bleeder valve:
Refer to "Components", CL-5.
CL-7
CLUTCH MASTER CYLINDER
Components
Components NFCL0007
SCL850
SCL743-C
CL-8
CLUTCH MASTER CYLINDER
Removal
Removal NFCL0008
1. Drain brake fluid.
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
2. Remove clutch tube using a flare nut wrench.
3. Remove snap pin between clutch pedal and push rod, and
remove clevis pin.
4. Unscrew master cylinder assembly mounting nuts and remove
master cylinder assembly from vehicle.
Installation NFCL0009
1. Connect clutch tube to master cylinder assembly, and hand-
tighten flare nut.
2. Install master cylinder assembly to vehicle, and tighten mount-
ing nuts to the specified torque.
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