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C TRANSMISSION/TRANSAXLE

SECTION CL CLUTCH
B

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

Revision: September 2005 CL-1 2006 Xterra
PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions for Clutch System ECS00DY3

G Recommended fluid is Genuine NISSAN Super Heavy Duty Brake Fluid or equivalent. Refer to MA-11,
"Fluids and Lubricants" .
G Do not reuse drained brake fluid.
G Be careful not to splash brake fluid on painted areas.
G Use flare nut wrench when removing and installing clutch piping.
G To clean or wash all parts of master cylinder and operating cylin-
der, use clean brake fluid.
G Do not use mineral oils such as gasoline or kerosene. They will
ruin rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not
use compressed air.

SBR686C

Revision: September 2005 CL-2 2006 Xterra
PREPARATION

PREPARATION PFP:00002
A
Special Service Tools ECS00DY4

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

ZZA0508D

ST20630000 Installing clutch disc E
(J-26366) a: 15.8 mm (0.622 in) dia.
Clutch aligning bar b: 22.9 mm (0.902 in) dia.
F

ZZA1178D
G
Commercial Service Tools ECS00DY5

Tool name Description H
Pin punch Removing and installing master cylinder
spring pin
Tip diameter: 4.5 mm (0.177 in) dia.
I

J
ZZA0515D

Power tool Loosening bolts and nuts

L
PBIC0190E

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

S-NT360

Revision: September 2005 CL-3 2006 Xterra
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

Revision: September 2005 CL-4 2006 Xterra
Symptom
CLUTCH

Reference page

Clutch slips
Clutch noisy

Revision: September 2005
Clutch pedal spongy
Clutch grabs/chatters
SUSPECTED PARTS (Possible cause)

Clutch does not disengage
NVH Troubleshooting Chart

CLUTCH PEDAL (Free play out of adjustment) CL-6

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

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

MASTER CYLINDER PISTON CUP (Damaged) CL-10

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

4
2
ENGINE MOUNTING (Loose) EM-105

CL-5
RELEASE BEARING (Worn, dirty or damaged) CL-14

1
CLUTCH DISC (Out of true) CL-16

5
CLUTCH DISC (Runout is excessive) CL-16

5
2 CLUTCH DISC (Lining broken) CL-16

5
CLUTCH DISC (Dirty or burned) CL-16

5
CLUTCH DISC (Oily) CL-16

5
2
2

CLUTCH DISC (Worn out) CL-16
2
2

CLUTCH DISC (Hardened) CL-16
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

CLUTCH DISC (Lack of spline grease) CL-16
5

DIAPHRAGM SPRING (Damaged) CL-16
6
3

DIAPHRAGM SPRING (Out of tip alignment) CL-16
6
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

PRESSURE PLATE (Distortion) CL-16
7
4

FLYWHEEL (Distortion) EM-133
5

2006 Xterra
ECS00DY6
PFP:00003

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

L
F

K
E
B
A

H
D

M
CLUTCH PEDAL

CLUTCH PEDAL PFP:46540

On-Vehicle Inspection and Adjustment ECS00DY7

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-7,
"Removal and Installation" .
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-8, "Bleeding" .
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.

SCL800

Revision: September 2005 CL-6 2006 Xterra
CLUTCH PEDAL

Removal and Installation ECS00DY8

WCIA0548E

1. Bracket 2. Bushing 3. Snap pin G
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
H

REMOVAL
1. Remove the clutch pedal bracket nuts from inside the engine compartment. I
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. J
4. Remove the pedal bracket bolt and then remove the clutch pedal assembly.
INSPECTION AFTER REMOVAL
K
G Inspect the clutch pedal for bends, damage, or cracked welds. Replace if necessary.
G Make sure that the assist spring and return spring have not lost their spring. Replace if necessary.
INSTALLATION L
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 M
the clutch pedal assembly in the vehicle and adjusting the pedal free play.

Revision: September 2005 CL-7 2006 Xterra
CLUTCH FLUID

CLUTCH FLUID PFP:00017

Bleeding ECS00DY9

CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected
area with water.
NOTE:
G 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.
G 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-11, "RECOMMENDED 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-11,
"Removal and Installation" . SCL203-A

Revision: September 2005 CL-8 2006 Xterra
CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER PFP:30610
A
Removal and Installation ECS00DYA

G
WCIA0438E

1. Nipple 2. Clamp 3. Reservoir hose
4. Cylinder body 5. Clutch tube 6. Dust cover H
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 I
16. Spring pin

REMOVAL
1. Remove the snap pin and clevis pin from the clevis, and separate it from the clutch pedal. J
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 K
affected area with water.
3. Remove the hose clamp and hose from the clutch master cylinder.
L
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 M
Installation is in the reverse order of removal.
G 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" : 120.5 mm (4.74 in)
G After installation, inspect and adjust the clutch pedal as neces-
sary, then bleed the clutch hydraulic system. Refer to CL-6, "On-
Vehicle Inspection and Adjustment" and CL-8, "Bleeding" .

SCIA5158E

Revision: September 2005 CL-9 2006 Xterra
CLUTCH MASTER CYLINDER

Disassembly and Assembly ECS00DYB

DISASSEMBLY
1. Remove the spring pin, using suitable tool.
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:
Clutch pedal height is controlled with the position of the clevis
and push rod.
4. Remove the dust cover from the cylinder body.
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.
6. Remove the piston assembly and return spring.
INSPECTION AFTER DISASSEMBLY
Inspect for the following, replace parts as necessary.
G Damage, foreign material, wear, corrosion, and pin holes on the cylinder inner surface
G Damaged or deformed nipple
G Weak spring
G Cracked or deformed dust cover
ASSEMBLY
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.
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 the dust cover to the cylinder body.
4. Install the reservoir seal and nipple to the cylinder body.
5. Install the clevis to the push rod.
6. Check and adjust the position of the clevis and push rod. After
adjusting "L", tighten lock nut to the specified torque. Refer to
CL-9, "Removal and Installation" .
Length "L"
(for QR25DE engine models) : 119.5 mm (4.70 in)
(for VQ40DE engine models) : 120.5 mm (4.74 in)

SCIA5158E

Revision: September 2005 CL-10 2006 Xterra
OPERATING CYLINDER

OPERATING CYLINDER PFP:30620
A
Removal and Installation ECS00DYC

G
WCIA0439E

1. Dust cover 2. Push rod 3. Piston
4. Piston cup 5. Piston spring 6. Air bleeder H
7. Clutch hose 8. Copper washer 9. Cylinder body

REMOVAL
1. Drain the brake fluid from the clutch hydraulic system. I
CAUTION:
Do not spill brake fluid on painted surfaces. If it spills, wipe up immediately and wash the affected
area with water. J
2. Remove the clutch hose and copper washer from the operating cylinder.
CAUTION:
Do not reuse the copper washer. K
3. Remove the operating cylinder bolts, and remove the operating cylinder from the vehicle.
INSTALLATION L
Installation is in the reverse order of removal.
G Tighten the clutch hose fitting to the specified torque. Refer to CL-11, "Removal and Installation" .
CAUTION: M
Make sure the clutch hose is not bent or twisted.
G After installation, bleed the clutch hydraulic system. Refer to CL-8, "Bleeding" .
Disassembly and Assembly ECS00DYD

DISASSEMBLY
G Remove the dust cover, push rod and piston assembly from the cylinder body.
INSPECTION AFTER DISASSEMBLY
Inspect for the following, replace parts as necessary.
G Damage, foreign material, wear, corrosion, and pinholes on the cylinder inner surface, piston, and sliding
part of piston cup
G Weak spring
G Cracked or deformed dust cover
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.

Revision: September 2005 CL-11 2006 Xterra
OPERATING CYLINDER

3. Apply rubber grease to the dust cover and install the push rod and dust cover.

Revision: September 2005 CL-12 2006 Xterra
CLUTCH PIPING

CLUTCH PIPING PFP:30650
A
Removal and Installation ECS00DYE

WCIA0440E

1. Clutch tube 2. Clutch orifice 3. Lock plate E
4. Clutch hose 5. Operating Cylinder 6. Master cylinder
7. Clutch pedal
F
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 G
area with water.
G When installing the clutch hose to the bracket, align the clutch
hose metal fittings with the bracket positioning emboss, then H
install the lock plate to secure.
CAUTION:
G Do not damage the clutch hose.
I
G Make sure the clutch hose is not bent or twisted.

G Tighten the clutch tube and hose fittings to the specified torque.
CAUTION: J
G Do not reuse the copper washer.

G Do not damage the clutch tube fittings or clutch tube. PCIB0681E

G After installation, bleed the air from the clutch hydraulic system. K
Refer to CL-8, "Bleeding" .

Revision: September 2005 CL-13 2006 Xterra
CLUTCH RELEASE MECHANISM

CLUTCH RELEASE MECHANISM PFP:30502

Removal and Installation ECS00DYG

LCIA0373E

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

REMOVAL
1. Remove the manual transmission from the vehicle. Refer to MT-17, "Removal and Installation from Vehi-
cle (For 2WD Models)" or MT-19, "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.
3. Remove the dust cover.
4. Remove the snap spring from the withdrawal lever.
5. Remove the release bearing from release bearing sleeve using
suitable tool.

CLA0013D

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

SCL733

Revision: September 2005 CL-14 2006 Xterra
CLUTCH RELEASE MECHANISM

INSTALLATION
Installation is in the reverse order of removal. A
NOTE:
G Install the release bearing to release bearing sleeve using suit-
able tool, as shown. B

WCL025
E
G Clean old grease and abrasive materials off the grease application areas.
G Apply grease to the specified points as shown.
F

SCIA1362E I
G Apply approximately 1 mm (0.04 in) thick coat of clutch sleeve grease to withdrawal lever and holder
spring frictional surfaces.
G Apply a coat of clutch sleeve grease to ball pin contact surface of the withdrawal lever and inner slots of J
the release bearing. The grease surface should be level with the surrounding area.
G 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. K
CAUTION:
G Before installing the manual transaxle to the vehicle, check that each sliding surface slides
smoothly by operating withdrawal lever. L
G Be careful not to bring any grease into contact with the clutch disc facing, pressure plate surface,
or flywheel surface.
G When assembling, make sure that both ends of the snap M
spring touch the end face of the withdrawal lever.
G Be careful with the orientation of the installation.

SCIA6903E

Revision: September 2005 CL-15 2006 Xterra
CLUTCH DISC, CLUTCH COVER

CLUTCH DISC, CLUTCH COVER PFP:30100

Removal and Installation ECS00DYH

WCIA0522E

1. Flywheel 2. Clutch disc 3. Clutch cover

CAUTION:
G Do not clean the clutch disc with solvent.
G When installing, do not get grease from the main drive shaft onto the clutch disc friction surface.
G If the flywheel is removed, align the dowel pin with the smallest hole of flywheel. Refer to EM-113,
"ASSEMBLY" .
REMOVAL
1. Remove the manual transmission from the vehicle. Refer to MT-17, "Removal and Installation from Vehi-
cle (For 2WD Models)" or MT-19, "Removal and Installation from Vehicle (For 4WD Models)" .
2. Remove the clutch cover bolts using power tool. Remove the clutch cover and clutch disc.
INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc
G Check the clutch disc for wear of facing.
Wear limit (depth to rivet head) :0.3 mm (0.012 in)

SCL229

Revision: September 2005 CL-16 2006 Xterra
CLUTCH DISC, CLUTCH COVER

G Measure the circumference runout at the point indicated. If it is
outside the specification, replace the clutch disc. A
Runout limit/diameter of the area to be measured
: 1.0 mm (0.039 in) or less/250 mm (9.84 in) dia.
B
G Measure the backlash of the clutch disc spline at the circumfer-
ence of the disc. If it is outside the specification, replace the
clutch disc. CL
Maximum backlash of spline (at outer disc : 1.0 mm
edge) (0.039 in) SCL221

D
Clutch Cover
With the clutch cover installed on the vehicle, check the diaphragm
spring toe height for unevenness. If they exceed the tolerance, E
adjust the height using Tool.
Uneven limit of diaphragm spring toe height : 0.7mm
(0.028 in) F

Tool number : ST20050240 ( -- )
G Check clutch cover thrust ring for wear or breakage. If wear or G
breakage is found, replace clutch cover assembly.
NOTE: PCIB0276E
G Worn thrust ring will generate a beating noise when tapped at H
the rivet with a hammer.
G Broken thrust ring will make a clinking sound when cover is shaken up and down.

G If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface, I
repair the surface with emery paper. If surface is damaged or distorted, replace the assembly.
Flywheel
J
G Check contact surface of flywheel for slight burns or discolora-
tion. If any are found, repair flywheel with emery paper.
G Check the flywheel runout. Refer to EM-133, "FLYWHEEL
DEFLECTION (M/T MODELS)" . K

M
PBIC2168E

Revision: September 2005 CL-17 2006 Xterra
CLUTCH DISC, CLUTCH COVER

INSTALLATION
1. Apply recommended grease to clutch disc and main drive shaft spline.
CAUTION:
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 steps in the order shown. Refer to CL-16, "Removal and Installation" .
First step : 15 N

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