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CLUTCH

C TRANSMISSION/TRANSAXLE

B
SECTION
CLUTCH CL

E
CONTENTS
PRECAUTIONS ......................................................... 2. Removal and Installation ....................................... 11 . F
Precautions for Battery Service ............................... 2 . REMOVAL .......................................................... 11
.
Service Notice or Precaution ................................... 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 ........................................................ 12
.
H
TROUBLESHOOTING ............................................... 4 . CLUTCH PIPING ...................................................... 13
.
NVH Troubleshooting Chart .................................... 4 . Removal and Installation ....................................... 13 .
CLUTCH PEDAL ....................................................... 5 . CLUTCH RELEASE MECHANISM .......................... 14 .
On-Vehicle Inspection and Adjustment ................... 5 . Removal and Installation ....................................... 14 . I
Removal and Installation ......................................... 6 . COMPONENTS .................................................. 14 .
COMPONENTS ................................................... 6 . REMOVAL .......................................................... 14
.
REMOVAL ............................................................ 6
. INSPECTION AFTER REMOVAL ...................... 14 . J
INSPECTION AFTER REMOVAL ........................ 6 . INSTALLATION .................................................. 15 .
INSTALLATION .................................................... 6 . CLUTCH DISC, CLUTCH COVER ........................... 16 .
CLUTCH FLUID ......................................................... 7
. Removal and Installation ....................................... 16 .
K
Bleeding .................................................................. 7
. COMPONENTS .................................................. 16 .
CLUTCH MASTER CYLINDER ................................. 8 . REMOVAL .......................................................... 16
.
Components ............................................................ 8
. INSPECTION AND ADJUSTMENT AFTER
Removal and Installation ......................................... 8 . REMOVAL .......................................................... 16
. L
REMOVAL ............................................................ 8
. INSTALLATION .................................................. 17 .
INSTALLATION .................................................... 9 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 18 .
Disassembly and Assembly .................................... 9 . Clutch Control System ........................................... 18 . M
DISASSEMBLY .................................................... 9 . Clutch Master Cylinder .......................................... 18 .
INSPECTION AFTER DISASSEMBLY .............. 10 . Clutch Operating Cylinder ..................................... 18 .
ASSEMBLY ........................................................ 10. Clutch Disc ............................................................ 18
.
OPERATING CYLINDER ..........................................11 . Clutch Cover .......................................................... 18
.
Components ...........................................................11
. Clutch Pedal .......................................................... 18
.

Revision: 2006 August CL-1 2007 G35 Coupe
PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions for Battery Service NCS0009V

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.
Service Notice or Precaution NCS0009W

q Recommended fluid is brake fluid "DOT 3". Refer to MA-10, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" .
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 cylinder
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

Revision: 2006 August CL-2 2007 G35 Coupe
PREPARATION

PREPARATION PFP:00002
A
Special Service Tools NCS0009X

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 NCS0009Y

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

S-NT360

Power tool Loosening bolts and nuts

PBIC0190E

Revision: 2006 August CL-3 2007 G35 Coupe
Symptom
Reference page

Revision: 2006 August
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-131

CL-4
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-165
5
PFP:00003

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

2007 G35 Coupe
NCS0009Z
CLUTCH PEDAL

CLUTCH PEDAL PFP:46540
A
On-Vehicle Inspection and Adjustment NCS000A0

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-verify 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 - 1.0 mm (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

SCL800
M

Revision: 2006 August CL-5 2007 G35 Coupe
CLUTCH PEDAL

Removal and Installation NCS000A1

COMPONENTS

SCIA7469E

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
Refer to GI-10, "Components" , and the followings for the symbols in the figure.
: Apply lithium-based grease including molybdenum disulphide.

REMOVAL
1. Remove kicking plate. Refer to EI-31, "Removal and Installation" .
2. Remove foot-rest. Refer to EI-34, "Removal and Installation" .
3. Remove dash side finisher. Refer to EI-31, "Removal and Installation" .
4. Remove instrument lower driver panel. Refer to IP-11, "Removal and Installation" .
5. Remove VDC/TCS/ABS control unit. Refer to BRC-59, "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 free play.

Revision: 2006 August CL-6 2007 G35 Coupe
CLUTCH FLUID

CLUTCH FLUID PFP:00017
A
Bleeding NCS000A2

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,
"Components" . PCIB1305J
G

Revision: 2006 August CL-7 2007 G35 Coupe
CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER PFP:30610

Components NCS001AD

SCIA7470E

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
Refer to GI-10, "Components" , and the followings for the symbols in the figure.
1: Apply lithium-based grease including molybdenum disulphide.
2: Apply rubber lubricant.
3: Apply silicone grease.

Removal and Installation NCS000A3

Revision: 2006 August CL-8 2007 G35 Coupe
CLUTCH MASTER CYLINDER

9. Remove reservoir tank.
10. Remove clutch tube using a flare nut wrench. A
11. Remove master cylinder assembly.

SCIA1587E

D
INSTALLATION
1. Check position of clevis and push rod. If measurement is outside
the standard length, adjust position of clevis and push rod.
E
Length "L": 110.5 mm (4.35 in)
2. Connect clutch tube to master cylinder assembly and tempo-
rarily tighten flare nut. F
3. Install master cylinder assembly and tighten mounting nuts to
the specified torque. Refer to CL-8, "Components" .
4. Tighten clutch tube flare nut to the specified torque using a flare G
nut torque wrench. Refer to CL-13, "Removal and Installation" .
SCIA5158E
5. Install clevis to clutch pedal, and fix clevis with clevis pin.
6. Install snap pin to clevis pin. H
7. Install reservoir hose to nipple. Install reservoir tank to vehicle,
and then tighten mounting nuts to the specified torque.
I
: 5.8 N

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