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CL


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TRANSMISSION & DRIVELINE




                                                                                                                                 CL
                                                                                                                                                                    A


                                                                                                                                                                    B
                                                                                                     SECTION
                                                                                                                                      CLUTCH                        C


                                                                                                                                                                    CL


                                                                                                                                                                    E
                                                                  CONTENTS
SYMPTOM DIAGNOSIS .............................. 2
                                            .                                        Removal and Installation ......................................... 9  .        F
                                                                                     Disassembly and Assembly ....................................10       .
NOISE, VIBRATION AND HARSHNESS                                                       Inspection ...............................................................10
                                                                                                                                                           .
(NVH) TROUBLESHOOTING ............................ 2
                                             .                                                                                                                      G
  NVH Troubleshooting Chart ..................................... 2
                                                           .                       OPERATING CYLINDER .................................. 11
                                                                                     Exploded View ........................................................11
                                                                                                                                                           .
PRECAUTION .............................................. 3
                                                     .                               Removal and Installation ........................................11   .
                                                                                     Disassembly and Assembly ....................................11       .        H
PRECAUTIONS .................................................. 3
                                                         .                           Inspection ...............................................................12
                                                                                                                                                           .
  Precaution for Supplemental Restraint System
  (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-                                          CLUTCH PIPING ............................................... 13                  I
  SIONER" .................................................................. 3
                                                                      .              Exploded View ........................................................13
                                                                                                                                                       .
  Precaution for Procedure without Cowl Top Cover 3                   ......         Removal and Installation ........................................13
                                                                                                                                                       .
  Service Notice or Precautions .................................. 3  .
                                                                                   REMOVAL AND INSTALLATION .............. 14
                                                                                                                       .                                             J
PREPARATION ........................................... 4
                                                   .
                                                                                   CLUTCH RELEASE MECHANISM ................... 14
PREPARATION .................................................. 4
                                                         .                           Exploded View ........................................................14
                                                                                                                                                           .        K
  Special Service Tool ................................................ 4
                                                                 .                   Removal and Installation ........................................14   .
  Commercial Service Tool ......................................... 4
                                                                 .                   Inspection ...............................................................15
                                                                                                                                                           .

ON-VEHICLE MAINTENANCE .................... 6
                                       .                                           CLUTCH DISC, CLUTCH COVER .................... 17                                 L
                                                                                     Exploded View ........................................................17
                                                                                                                                                       .
CLUTCH PEDAL ................................................ 6
                                                        .                            Removal and Installation ........................................17
                                                                                                                                                       .
  On-Vehicle Inspection and Adjustment .................... 6
                                                     .                               Inspection and Adjustment .....................................18 .            M
CLUTCH FLUID .................................................. 7
                                                          .                        SERVICE DATA AND SPECIFICATIONS
  Bleeding ................................................................... 7
                                                                        .          (SDS) ........................................................... 20
                                                                                                                                                 .
                                                                                                                                                                    N
ON-VEHICLE REPAIR ................................. 8
                                               .                                   SERVICE DATA AND SPECIFICATIONS
CLUTCH PEDAL ................................................ 8
                                                        .                          (SDS) ................................................................. 20
                                                                                     Clutch Control System ............................................20 .         O
  Exploded View ......................................................... 8
                                                                        .
                                                                                     Clutch Master Cylinder ...........................................20 .
  Removal and Installation .......................................... 8 .
                                                                                     Clutch Operating Cylinder ......................................20   .
  Inspection ................................................................. 8
                                                                        .
                                                                                     Clutch Disc .............................................................20
                                                                                                                                                          .         P
CLUTCH MASTER CYLINDER .......................... 9
                                            .                                        Clutch Cover ...........................................................20
                                                                                                                                                          .
  Exploded View ......................................................... 9
                                                                   .                 Clutch Pedal ...........................................................20
                                                                                                                                                          .




Revision: October 2008                                                        CL-1                                                               2009 Xterra
                                                                    Symptom
                                                                                                                                                                                                              CLUTCH


                                                                                                                                                                                             Reference page




Revision: October 2008
                                                     Clutch slips
                                                                    Clutch noisy
                                                                                                                                                                                                                                                                                                                                                                                                                                             < SYMPTOM DIAGNOSIS >




                                                                                   Clutch pedal spongy
                                                                                                         Clutch grabs/chatters
                                                                                                                                                         SUSPECTED PARTS (Possible cause)
                                                                                                                                                                                                                                                                                                                                      NVH Troubleshooting Chart




                         Clutch does not disengage
                                                                                                                                 CLUTCH PEDAL (Free play out of adjustment)                  CL-6




                         1
                                                     1
                                                                                                                                                                                                                                                                                                                                                                                                                         SYMPTOM DIAGNOSIS




                                                                                                                                 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-102




                                                                                                         1




CL-2
                                                                                                                                 RELEASE BEARING (Worn, dirty or damaged)                   CL-14




                                                                    1
                                                                                                                                 CLUTCH DISC (Out of true)                                  CL-17




                         5
                                                                                                                                 CLUTCH DISC (Runout is excessive)                          CL-17




                         5
                                                                                                         2
                                                                                                                                 CLUTCH DISC (Lining broken)                                CL-17




                         5
                                                                                                                                 CLUTCH DISC (Dirty or burned)                              CL-17




                         5
                                                                                                                                 CLUTCH DISC (Oily)                                         CL-17




                         5
                                                                                                         2




                                                     2
                                                                                                                                 CLUTCH DISC (Worn out)                                     CL-17
                                                                                                         2




                                                     2
                                                                                                                                 CLUTCH DISC (Hardened)                                     CL-17
                                                                                                         2




                                                                                                                                 CLUTCH DISC (Lack of spline grease)                        CL-17
                         5
                         6                                                                                                       DIAPHRAGM SPRING (Damaged)                                 CL-17
                                                     3



                                                                                                                                 DIAPHRAGM SPRING (Out of tip alignment)                    CL-17
                         6
                                                                                                         2
                                                                                                                                                                                                                                                                                                                                                                                                                                                                     NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING



                                                                                                                                                                                                                                                                                                                                                                  NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING




                                                                                                                                 PRESSURE PLATE (Distortion)                                CL-17
                         7
                                                     4




                                                                                                                                 FLYWHEEL (Distortion)                                      EM-117
                                                     5




2009 Xterra
                                                                                                                                                                                                                       Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
                                                                                                                                                                                                                                                                                                                                        INFOID:0000000004064164
                                                 PRECAUTIONS
< PRECAUTION >
PRECAUTION                                                                                                                          A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT                                                         B
PRE-TENSIONER"                                                                                            INFOID:0000000004064165



The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along C
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.                    CL
Information necessary to service the system safely is included in the SR and SB section of this Service Man-
ual.
WARNING:                                                                                                                      E



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