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CLUTCH

C TRANSMISSION/TRANSAXLE

SECTION CL CLUTCH
B

E
CONTENTS
PRECAUTIONS ......................................................... 2 . INSTALLATION .................................................. 11 . F
Precautions for Battery Service ............................... 2 . Disassembly and Assembly ................................... 11 .
Caution .................................................................... 2
. DISASSEMBLY .................................................. 11 .
PREPARATION .......................................................... 3. INSPECTION AFTER DISASSEMBLY ............... 11 . G
Special Service Tools .............................................. 3 . ASSEMBLY ........................................................ 11
.
Commercial Service Tools ....................................... 3 . CLUTCH PIPING ...................................................... 12
.
NOISE, VIBRATION AND HARSHNESS (NVH) Removal and Installation ....................................... 12 .
H
TROUBLESHOOTING ............................................... 4 . CLUTCH RELEASE MECHANISM .......................... 13 .
NVH Troubleshooting Chart .................................... 4 . Removal and Installation ....................................... 13 .
CLUTCH PEDAL ....................................................... 5 . REMOVAL .......................................................... 13
.
On-Vehicle Inspection and Adjustment ................... 5 . INSPECTION AFTER REMOVAL ...................... 13 . I
Removal and Installation ......................................... 6 . INSTALLATION .................................................. 14 .
REMOVAL ............................................................ 6
. CLUTCH DISC, CLUTCH COVER ........................... 15 .
INSPECTION AFTER REMOVAL ........................ 6 . Removal and Installation (M/T Model Code Num- J
INSTALLATION .................................................... 6 . ber: CD008) ........................................................... 15
.
CLUTCH FLUID ......................................................... 7. REMOVAL .......................................................... 15
.
Bleeding .................................................................. 7
. INSPECTION AND ADJUSTMENT AFTER
K
CLUTCH MASTER CYLINDER ................................. 8 . REMOVAL .......................................................... 15
.
Removal and Installation ......................................... 8 . INSTALLATION .................................................. 16 .
REMOVAL ............................................................ 8
. Removal and Installation (M/T Model Code Num-
INSTALLATION .................................................... 9 . ber: CD009) ........................................................... 17
. L
Disassembly and Assembly .................................... 9 . REMOVAL .......................................................... 17
.
DISASSEMBLY .................................................... 9 . INSPECTION AND ADJUSTMENT AFTER
INSPECTION AFTER DISASSEMBLY .............. 10 . REMOVAL .......................................................... 17
. M
ASSEMBLY ........................................................ 10 . INSTALLATION .................................................. 18 .
OPERATING CYLINDER ..........................................11 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 19 .
Removal and Installation ........................................11 . Clutch Control System ........................................... 19 .
REMOVAL ...........................................................11. Clutch Master Cylinder .......................................... 19 .
Clutch Operating Cylinder ..................................... 19 .
Clutch Disc ............................................................ 19
.
Clutch Cover .......................................................... 19
.
Clutch Pedal .......................................................... 19
.

Revision: 2005 August CL-1 2005 350Z
PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions for Battery Service ACS006FW

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.
Caution ACS004MV

q Recommended fluid is brake fluid "DOT 3". Refer to MA-12, "RECOMMENDED FLUIDS AND
LUBRICANTS" .
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

Revision: 2005 August CL-2 2005 350Z
PREPARATION

PREPARATION PFP:00002
A
Special Service Tools ACS004MW

The actual shapes of Kent-Moore tool 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 ACS004MX

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

S-NT360

Power tool Loosening bolts and nuts

PBIC0190E

Revision: 2005 August CL-3 2005 350Z
page

Symptom
Reference

CD009
CD008

Revision: 2005 August
Clutch slips
Clutch noisy
Clutch pedal spongy
Clutch grabs/chatters
SUSPECTED PARTS (Possible cause)
M/T model code number:
M/T model code number:

Clutch does not disengage
NVH Troubleshooting Chart

CLUTCH PEDAL (Free play out of 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-132

CL-4
RELEASE BEARING (Worn, dirty or damaged) CL-13

1
CLUTCH DISC (Out of true)

5
CLUTCH DISC (Runout is excessive)

5
2
CLUTCH DISC (Lining broken)

5
CLUTCH DISC (Dirty or burned)

5
CLUTCH DISC (Oily)

5
2
2

CLUTCH DISC (Worn out) CL-17 CL-15
2
2

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

CLUTCH DISC (Lack of spline grease)
5

DIAPHRAGM SPRING (Damaged)
6
3

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

PRESSURE PLATE (Distortion)
7
4

FLYWHEEL (Distortion) EM-167
5
PFP:00003

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

2005 350Z
ACS004MY
CLUTCH PEDAL

CLUTCH PEDAL PFP:46540
A
On-Vehicle Inspection and Adjustment ACS004MZ

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. B
a. If the clevis pin is not free, check that the ASCD clutch switch is
not applying pressure to the clutch pedal causing the clevis pin
to bind. To adjust, loosen lock nut and turn ASCD clutch switch.
CL
b. Tighten the lock nut.
c. Verify that the clevis pin floats in the bore of the clutch pedal. It
should not be bound by the clutch pedal. D
d. If the clevis pin is still not free, remove the clevis pin and check
for deformation or damage. Replace clevis pin if necessary. PCIB0758E
Leave pin removed for step 2.
E
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 related parts (clutch pedal bracket, assist spring, bushing etc.). Re- F
assemble the clutch pedal and re-verify that the clevis pin floats freely in the bore of the 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
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

PCIB0757E
M

Revision: 2005 August CL-5 2005 350Z
CLUTCH PEDAL

Removal and Installation ACS004N0

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-35, "Removal and Installation (for Coupe Models)" or EI-37, "Removal
and Installation (for Roadster Models)" .
2. Remove footrest. Refer to EI-43, "Removal and Installation" .
3. Remove dash side finisher (LH). Refer to IP-11, "Removal and Installation" .
4. Remove instrument driver panel lower. Refer to IP-11, "Removal and Installation" .
5. Remove VDC/TCS/ABS control unit. (VDC/TCS/ABS models) Refer to BRC-147, "Removal and Installa-
tion" .
6. Remove the clutch interlock switch and ASCD clutch switch connectors and harness.
7. Remove the snap pin and clevis pin.
8. Remove the pedal bracket mounting bolt and nuts and then remove the 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 the 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 the clutch interlock switch, adjust the switch position.
NOTE:
Tighten the ASCD clutch switch lock nut to the specified torque after installing the clutch pedal assembly in the
vehicle and adjusting the pedal free play.

Revision: 2005 August CL-6 2005 350Z
CLUTCH FLUID

CLUTCH FLUID PFP:00017
A
Bleeding ACS004N1

CAUTION:
q Monitor fluid level in the 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 a vacuum assist or
power bleeder will not purge all the air from the system.
1. Fill the master cylinder reservoir tank with new clutch fluid. D
2. Connect a transparent vinyl hose to the air bleeder.
3. Depress the clutch pedal quickly and fully a few times and hold
it. E
4. With clutch pedal depressed, open air bleeder to release air.
5. Close air bleeder.
6. Release clutch pedal and wait for 5 seconds. F
7. Repeat steps 3 to 6 until no bubbles can be observed in the
brake fluid.
8. Tighten air bleeder to the specified torque. Refer to CL-11, SCIA1496E
G
"Removal and Installation" .

Revision: 2005 August CL-7 2005 350Z
CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER PFP:30610

Removal and Installation ACS004N2

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-35, "Removal and Installation (for Coupe Models)" or EI-37, "Removal
and Installation (for Roadster Models)" .
2. Remove footrest. Refer to EI-43, "Removal and Installation" .
3. Remove dash side finisher. Refer to IP-11, "Removal and Installation" .
4. Remove instrument driver panel lower. Refer to IP-11, "Removal and Installation" .
5. Remove VDC/TCS/ABS control unit. (VDC/TCS/ABS models) Refer to BRC-147, "Removal and Installa-
tion" .
6. Remove snap pin and clevis pin from the 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: 2005 August CL-8 2005 350Z
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.
3. Tighten clutch tube flare nut to the specified torque using a flare nut torque wrench. Refer to CL-12,
"Removal and Installation" . B
4. Install clevis to the clutch pedal, and fix clevis with clevis pin.
5. Install snap pin to the clevis pin.
CL
6. Install reservoir hose to the nipple. Install the reservoir tank to
the vehicle, and then tighten mounting nuts to the specified
torque.
D
: 5.8 N

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