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CLUTCH

C TRANSMISSION/TRANSAXLE

SECTION CL CLUTCH
B

E
CONTENTS
PRECAUTIONS ......................................................... 2. INSTALLATION .................................................... 9. F
Precautions for Battery Service ............................... 2 . Disassembly and Assembly ..................................... 9 .
Service Notice or Precautions ................................. 2 . DISASSEMBLY .................................................... 9 .
PREPARATION .......................................................... 3
. INSPECTION AFTER DISASSEMBLY ................. 9 . G
Special Service Tools .............................................. 3. ASSEMBLY ........................................................ 10
.
Commercial Service Tools ....................................... 3 . CSC (CONCENTRIC SLAVE CYLINDER) ............... 11 .
NOISE, VIBRATION AND HARSHNESS (NVH) Removal and Installation ....................................... 11 .
H
TROUBLESHOOTING ............................................... 4 . COMPONENTS .................................................. 11 .
NVH Troubleshooting Chart .................................... 4 . REMOVAL .......................................................... 11
.
CLUTCH PEDAL ....................................................... 5 . INSTALLATION .................................................. 13 .
On-Vehicle Inspection and Adjustment ................... 5 . CLUTCH PIPING ...................................................... 15
. I
Removal and Installation ......................................... 6 . Removal and Installation ....................................... 15 .
COMPONENTS ................................................... 6 . CLUTCH DISC, CLUTCH COVER ........................... 16 .
REMOVAL ............................................................ 6
. Removal and Installation ....................................... 16 . J
INSPECTION AFTER REMOVAL ........................ 6 . COMPONENTS .................................................. 16 .
INSTALLATION .................................................... 6 . REMOVAL .......................................................... 16
.
CLUTCH FLUID ......................................................... 7
. INSPECTION AND ADJUSTMENT AFTER
K
Bleeding .................................................................. 7
. REMOVAL .......................................................... 17
.
CLUTCH MASTER CYLINDER ................................. 8 . INSTALLATION .................................................. 17 .
Components ............................................................ 8
. SERVICE DATA AND SPECIFICATIONS (SDS) ..... 19 .
Removal and Installation ......................................... 8 . Clutch Control System ........................................... 19 . L
REMOVAL ............................................................ 8
. Clutch Master Cylinder .......................................... 19 .
Clutch Disc ............................................................ 19
.
Clutch Cover .......................................................... 19
. M
Clutch Pedal .......................................................... 19
.

Revision: 2006 November CL-1 2007 350Z
PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions for Battery Service NCS00001

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 Precautions NCS00002

q Recommended clutch fluid is brake fluid "DOT 3". Refer to MA-11, "RECOMMENDED FLUIDS AND
LUBRICANTS" .
q Never reuse drained clutch fluid.
q Be careful not to splash clutch fluid on painted areas.
q When removing clutch tube, use a flare nut wrench.
q When installing clutch tube, use a flare nut torque wrench.
q Use new clutch fluid to clean or wash all parts of master cylinder.
q Never use mineral oils such as gasoline or kerosene. It will ruin
the rubber parts of the hydraulic system.
q If transmission assembly is removed from the vehicle, always
replace CSC (Concentric Slave Cylinder) body and CSC tube.
Return CSC body insert to original position to remove transmis-
sion assembly. Dust on clutch disc sliding parts may damage
seal of CSC body and may cause clutch fluid leakage. SBR686C
q Do not disassemble CSC body.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not use compressed air.

Revision: 2006 November CL-2 2007 350Z
PREPARATION

PREPARATION PFP:00002
A
Special Service Tools NCS00003

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
CL
( -- ) clutch cover
Diaphragm adjusting wrench

ZZA0508D

ST20670000 Installing clutch disc
E
( -- )
Clutch aligning bar
a: 15 mm (0.59 in) dia.
F
b: 23 mm (0.91 in) dia.

ZZA1178D
G
Commercial Service Tools NCS00004

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

J
ZZA0515D

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

S-NT360

Power tool Loosening bolts and nuts M

PBIC0190E

Revision: 2006 November CL-3 2007 350Z
Symptom
Reference page

Clutch slips
Clutch noisy

Revision: 2006 November
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-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
CSC (Concentric Slave Cylinder) (Worn, dirty or damaged) CL-11

4
1
2
ENGINE MOUNTING (Loose) EM-101

CL-4
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-16
2
2

CLUTCH DISC (Hardened)
2

CLUTCH DISC (Lack of spline grease)
5
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

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-134
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 350Z
NCS00005
CLUTCH PEDAL

CLUTCH PEDAL PFP:46540
A
On-Vehicle Inspection and Adjustment NCS00006

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 pedal stopper bolt or
ASCD clutch switch is not applying pressure to the clutch pedal
causing the clevis pin to bind. To adjust, loosen lock nut and turn
CL
pedal stopper bolt or ASCD clutch switch.
b. Tighten the lock nut. Refer to CL-6, "Removal and Installation" .
c. Verify that the clevis pin floats in the bore of the clutch pedal. It D
should not be bound by the clutch pedal.
d. If the clevis pin is still not free, remove the clevis pin and check PCIB0907E
for deformation or damage. Replace clevis pin if necessary.
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.
F
b. If any sticking is noted, replace the related parts (clutch pedal assembly, bushing etc.). Re-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
G
clutch interlock switch)
Clearance C : 0.1 - 1.0 mm (0.004 - 0.039 in)
4. Check clutch hydraulic and system components (clutch master H
cylinder, CSC, 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

M
PCIB0757E

Revision: 2006 November CL-5 2007 350Z
CLUTCH PEDAL

Removal and Installation NCS00007

COMPONENTS

PCIB1678E

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 (With ASCD) 9. Pedal stopper bolt (Without ASCD)
10. Bushing 11. Snap pin
Refer to GI-11, "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-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 the clutch interlock switch and ASCD clutch switch (with ASCD) connectors and harness.
6. Remove the snap pin and clevis pin.
7. Remove the pedal bracket mounting bolt and nuts and then remove the clutch pedal assembly.
INSPECTION AFTER REMOVAL
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
Note the following, and install in the reverse order of removal.
q Tighten pedal stopper bolt lock nut or ASCD clutch switch lock nut to the specified torque after installing
the clutch pedal assembly in the vehicle and adjusting the pedal free play. Refer to CL-5, "On-Vehicle
Inspection and Adjustment" .
q After installing the clutch interlock switch, adjust the switch position. Refer to CL-5, "On-Vehicle Inspection
and Adjustment" .

Revision: 2006 November CL-6 2007 350Z
CLUTCH FLUID

CLUTCH FLUID PFP:00017
A
Bleeding NCS00008

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 valve.
3. Depress clutch pedal slowly and fully several times at an interval
of 2 to 3 seconds and hold it. E
4. With clutch pedal depressed, open air bleeder valve to release
air.
5. Close air bleeder valve. F
6. Release clutch pedal and wait for 5 seconds.
7. Repeat steps 3 to 6 until no bubbles can be observed in the
clutch fluid. PCIB1900E
G
8. Tighten air bleeder valve to the specified torque. Refer to CL-11,
"COMPONENTS" .
H

Revision: 2006 November CL-7 2007 350Z
CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER PFP:30610

Components NCS001A1

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-11, "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 NCS00009

Revision: 2006 November CL-8 2007 350Z
CLUTCH MASTER CYLINDER

8. Remove reservoir tank mounting nut and then remove reservoir
tank. A
9. Remove clutch tube using a flare nut wrench.
10. Remove mounting nuts and then remove packing and master
cylinder assembly. B

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" : 111.0

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