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CLUTCH
C TRANSMISSION/TRANSAXLE
A
SECTION CL CLUTCH
B
CL
D
E
CONTENTS
PRECAUTIONS ......................................................... 2 . Removal and Installation ....................................... 11 . F
Caution .................................................................... 2
. REMOVAL .......................................................... 11
.
Precautions for Battery Service ............................... 2 . INSTALLATION .................................................. 11 .
PREPARATION .......................................................... 3. Disassembly and Assembly ................................... 11 . G
Special Service Tools .............................................. 3 . DISASSEMBLY .................................................. 11 .
Commercial Service Tools ....................................... 3 . INSPECTION AFTER DISASSEMBLY ............... 11 .
NOISE, VIBRATION AND HARSHNESS (NVH) ASSEMBLY ........................................................ 11
.
H
TROUBLESHOOTING ............................................... 4 . CLUTCH PIPING ...................................................... 12
.
NVH Troubleshooting Chart .................................... 4 . Removal and Installation ....................................... 12 .
CLUTCH ............................................................... 4
. CLUTCH RELEASE MECHANISM .......................... 13 .
CLUTCH PEDAL ....................................................... 5 . Removal and Installation ....................................... 13 . I
On-Vehicle Inspection and Adjustment ................... 5 . REMOVAL .......................................................... 13
.
Removal and Installation ......................................... 6 . INSPECTION AFTER REMOVAL ...................... 13 .
REMOVAL ............................................................ 6
. INSTALLATION .................................................. 14 . J
INSPECTION AFTER REMOVAL ........................ 6 . CLUTCH DISC, CLUTCH COVER ........................... 15 .
INSTALLATION .................................................... 6 . Removal and Installation ....................................... 15 .
CLUTCH FLUID ......................................................... 7. REMOVAL .......................................................... 15
.
K
Bleeding .................................................................. 7
. INSPECTION AND ADJUSTMENT AFTER
CLUTCH MASTER CYLINDER ................................. 8 . REMOVAL .......................................................... 15
.
Removal and Installation ......................................... 8 . INSTALLATION .................................................. 16 .
REMOVAL ............................................................ 8
. SERVICE DATA AND SPECIFICATIONS (SDS) ..... 17 . L
INSTALLATION .................................................... 9 . Clutch Control System ........................................... 17 .
Disassembly and Assembly .................................... 9 . Clutch Master Cylinder .......................................... 17 .
DISASSEMBLY .................................................... 9 . Clutch Operating Cylinder ..................................... 17 . M
INSPECTION AFTER DISASSEMBLY .............. 10 . Clutch Disc ............................................................ 17
.
ASSEMBLY ........................................................ 10 . Clutch Cover .......................................................... 17
.
OPERATING CYLINDER ..........................................11 . Clutch Pedal .......................................................... 17
.
Revision; 2004 April CL-1 2003 G35 Coupe
PRECAUTIONS
PRECAUTIONS PFP:00001
Caution ACS006EJ
q Recommended fluid is brake fluid "DOT 3".
q Never reuse drained brake fluid.
q Be careful not to splash brake fluid on painted areas.
q When removing and installing clutch piping, use Tool.
q Use new brake fluid to clean or wash all parts of master cyl-
inder and operating cylinder.
q 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
Precautions for Battery Service ACS006EK
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.
Revision; 2004 April CL-2 2003 G35 Coupe
PREPARATION
PREPARATION PFP:00002
A
Special Service Tools ACS006EL
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
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 ACS006EM
J
Tool name Description
Pin punch Removing and installing master cylinder
Tip diameter: 4.5 mm (0.177 in) dia. spring pin K
L
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 April CL-3 2003 G35 Coupe
Symptom
CLUTCH
Reference page
Revision; 2004 April
Clutch slips
Clutch noisy
Clutch pedal spongy
Clutch grabs/chatters
SUSPECTED PARTS (Possible cause)
Clutch does not disengage
NVH Troubleshooting Chart
CLUTCH PEDAL (Inspection and 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-93
1
CL-4
RELEASE BEARING (Worn, dirty or damaged) CL-13
1
CLUTCH DISC (Out of true) CL-15
5
CLUTCH DISC (Runout is excessive) CL-15
5
2
CLUTCH DISC (Lining broken) CL-15
5
CLUTCH DISC (Dirty or burned) CL-15
5
CLUTCH DISC (Oily) CL-15
5
2
2
2 CLUTCH DISC (Worn out) CL-15
2
CLUTCH DISC (Hardened) CL-15
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
CLUTCH DISC (Lack of spline grease) CL-15
5
DIAPHRAGM SPRING (Damaged) CL-15
6
3
DIAPHRAGM SPRING (Out of tip alignment) CL-15
6
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
PRESSURE PLATE (Distortion) CL-15
7
4
FLYWHEEL (Distortion) EM-123
5
PFP:00003
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
2003 G35 Coupe
ACS006EN
CLUTCH PEDAL
CLUTCH PEDAL PFP:46540
A
On-Vehicle Inspection and Adjustment ACS006EO
1. Check to see if clevis pin floats freely in the bore of clutch pedal.
It should not be bound by clevis or clutch pedal. B
a. If clevis pin is not free, check that ASCD clutch switch is not
applying pressure to clutch pedal causing clevis pin to bind. To
adjust, loosen lock nut and turn ASCD clutch switch.
CL
b. Tighten lock nut.
c. Verify that clevis pin floats in the bore of clutch pedal. It should
not be bound by clutch pedal. D
d. If clevis pin is still not free, remove clevis pin and check for
deformation or damage. Replace clevis pin if necessary. Leave PCIB0680E
pin removed for step 2.
E
2. Check clutch pedal stroke for free range of movement.
a. With clevis pin removed, manually move 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 clutch pedal and re-verfity that clevis pin floats freely in the bore of 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 H
cylinder, clutch operating cylinder, clutch withdrawal lever, clutch
release bearing, etc.) for sticking or binding.
a. If any sticking or binding noted, repair or replace related parts as I
necessary.
b. If hydraulic system repair was necessary, bleed the clutch
hydraulic system. Refer to CL-7, "Bleeding" . J
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 K
purge all the air from the system.
L
SCL800
M
Revision; 2004 April CL-5 2003 G35 Coupe
CLUTCH PEDAL
Removal and Installation ACS006EP
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-32, "Removal and Installation" .
2. Remove foot-rest. Refer to EI-35, "Removal and Installation" .
3. Remove dash side finisher. Refer to EI-32, "Removal and Installation" .
4. Remove instrument lower driver panel. Refer to IP-11, "Removal and Installation" .
5. Remove VDC/TCS/ABS control unit. (VDC/TCS/ABS model) Refer to BRC-65, "Removal and Installation"
.
6. Remove clutch interlock switch and ASCD clutch switch connector and harness.
7. Remove snap pin and clevis pin.
8. Remove pedal bracket mounting bolt and nuts and then remove clutch pedal assembly.
INSPECTION AFTER REMOVAL
q Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace clutch pedal assembly.
INSTALLATION
To install, reverse the removal procedure, following the cautions below:
q Install clutch pedal assembly and adjust the pedal height. Tighten ASCD clutch switch lock nut to the
specified torque.
q After installing clutch interlock switch, adjust the switch position.
NOTE:
Tighten ASCD clutch switch lock nut to the specified torque after installing clutch pedal assembly in vehicle
and adjusting the pedal height.
Revision; 2004 April CL-6 2003 G35 Coupe
CLUTCH FLUID
CLUTCH FLUID PFP:00017
A
Bleeding ACS006EQ
CAUTION:
q Monitor fluid level in reservoir tank to make sure it does not empty. B
q 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 vacuum assist or power
bleeder will not purge all the air from the system.
1. Fill master cylinder reservoir tank with new clutch fluid. D
2. Connect a transparent vinyl hose to air bleeder.
3. Depress clutch pedal quickly and fully a few times and hold it.
4. With clutch pedal depressed, open air bleeder. E
5. Close air bleeder.
6. Release clutch pedal and wait for 5 seconds.
7. Repeat steps 3 to 6 until no bubbles can be observed in brake F
fluid.
8. Tighten air bleeder to the specified torque. Refer to CL-11,
"Removal and Installation" . SCIA1496E
G
H
I
J
K
L
M
Revision; 2004 April CL-7 2003 G35 Coupe
CLUTCH MASTER CYLINDER
CLUTCH MASTER CYLINDER PFP:30610
Removal and Installation ACS006ER
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-32, "Removal and Installation" .
2. Remove foot-rest. Refer to EI-35, "Removal and Installation" .
3. Remove dash side finisher. Refer to EI-32, "Removal and Installation" .
4. Remove instrument lower driver panel. Refer to IP-11, "Removal and Installation" .
5. Remove VDC/TCS/ABS control unit. (VDC/TCS/ABS model) Refer to BRC-65, "Removal and Installation"
.
6. Remove snap pin and clevis pin from 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 April CL-8 2003 G35 Coupe
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. Refer to CL-8,
"Removal and Installation" .
3. Tighten clutch tube flare nut to the specified torque using a flare nut torque wrench. Refer to CL-12, B
"Removal and Installation" .
4. Install clevis to clutch pedal, and fix clevis with clevis pin.
5. Install snap pin to clevis pin. CL
6. Install reservoir hose to nipple. Install reservoir tank to vehicle,
and then tighten mounting nuts to the specified torque.
D
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