Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Frontier 1998-2002 Approved Nissan Frontier 2000 KA24DE CL
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CLUTCH GI
SECTION CL MA
EM
LC
EC
CONTENTS
FE
PRECAUTIONS AND PREPARATION............................2 HYDRAULIC CLUTCH CONTROL .................................8
Precautions ..................................................................2 Clutch Master Cylinder (With clutch damper) .............8
Special Service Tools ..................................................2 Operating Cylinder.......................................................9 CL
Commercial Service Tools ...........................................2 CLUTCH RELEASE MECHANISM ...............................10
NOISE, VIBRATION AND HARSHNESS (NVH) CLUTCH DISC AND CLUTCH COVER ........................13
TROUBLESHOOTING .....................................................3 Clutch Disc.................................................................13 MT
NVH Troubleshooting Chart.........................................3 Clutch Cover and Flywheel .......................................14
CLUTCH SYSTEM...........................................................4 SERVICE DATA AND SPECIFICATIONS (SDS) ..........15
Clutch Pedal ................................................................5 General Specifications...............................................15 AT
INSPECTION AND ADJUSTMENT .................................6 Clutch Control System ..........................................15
Adjusting Clutch Pedal ................................................6 Inspection and Adjustment ........................................15
Air Bleeding Procedure................................................7
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX
PRECAUTIONS AND PREPARATION
Precautions
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 a suit-
able tool.
q Use new brake fluid to clean or wash all parts of master
cylinder, operating cylinder and clutch damper.
q Never use mineral oils such as gasoline or kerosene. They
will ruin the rubber parts of the hydraulic system.
SBR686C WARNING:
After cleaning the clutch disc, wipe it with a dust collector. Do
not use compressed air.
Special Service Tools
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.) Description
Tool name
ST20630000 Installing clutch cover and clutch disc
(J26366)
Clutch aligning bar
a: 15.9 mm (0.626 in) dia.
b: 22.8 mm (0.898 in) dia.
NT405 c: 55 mm (2.17 in)
ST20050240 Adjusting unevenness of clutch cover dia-
( -- ) phragm spring
Diaphragm spring
adjusting wrench
a: 150 mm (5.91 in)
NT404 b: 25 mm (0.98 in)
Commercial Service Tools
Tool name Description
1 Flare nut crowfoot Removing and installing clutch piping
2 Torque wrench
NT223 a: 10 mm (0.39 in)
Bearing puller Removing release bearing
NT077
Bearing drift Installing release bearing
a: 52 mm (2.05 in) dia.
NT474 b: 45 mm (1.77 in) dia.
CL-2
Reference page
(Possible cause)
SUSPECTED PARTS
Clutch slips
Symptom Clutch noisy
Clutch pedal spongy
Clutch grabs/chatters
Clutch does not disengage
1
1
CLUTCH PEDAL (Free play out of adjustment) CL-6
2
1
CLUTCH LINE (Air in line) CL-7
tion. If necessary, repair or replace these parts.
3
2
MASTER CYLINDER PISTON CUP (Damaged) CL-8
4
2
OPERATING CYLINDER PISTON CUP (Damaged) CL-9
1
ENGINE MOUNTING (Loose) Refer to EM section
CL-3
1
RELEASE BEARING (Worn, dirty or damaged) CL-10
5
CLUTCH DISC (Out of true) CL-13
2
5
CLUTCH DISC (Runout is excessive) CL-13
5
CLUTCH DISC (Lining broken) CL-13
5
CLUTCH DISC (Dirty or burned) CL-13
2
2
5
CLUTCH DISC (Oily) CL-13
NVH Troubleshooting Chart
2
2
CLUTCH DISC (Worn out) CL-13
2
CLUTCH DISC (Hardened) CL-13
5
CLUTCH DISC (Lack of spline grease) CL-13
3
6
DIAPHRAGM SPRING (Damaged) CL-14
2
6
DIAPHRAGM SPRING (Out of tip alignment) CL-14
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
4
7
CLUTCH COVER (Distortion) CL-14
5
FLYWHEEL (Distortion) CL-14
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
GI
TF
AT
EL
FE
ST
FA
BT
LC
RS
EC
RA
PD
CL
HA
BR
MT
EM
MA
IDX
CLUTCH SYSTEM
ACL096
CL-4
CLUTCH SYSTEM
Clutch Pedal GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
ACL093
PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX
CL-5
INSPECTION AND ADJUSTMENT
Adjusting Clutch Pedal
1. Adjust pedal height with pedal stopper bolt or ASCD clutch
switch.
Pedal height ``H'':
221 - 231 mm (8.70 - 9.09 in)
ACL075
2. Adjust pedal free play by turning master cylinder push rod.
Then tighten lock nut.
Pedal free play ``A'':
9 - 16 mm (0.35 - 0.63 in)
Pedal free play, measured at pedal pad includes the following:
q Free play due to clevis pin and clevis pin hole, push rod
and master cylinder.
3. Make sure that clevis pin can rotate smoothly.
If not, readjust pedal free play with master cylinder push rod.
ACL076
CL-6
INSPECTION AND ADJUSTMENT
Adjusting Clutch Pedal (Cont'd)
4. Adjust clearance ``C'' shown in the figure while fully depress- GI
ing clutch pedal.
Clearance ``C'':
0.1 - 1.0 mm (0.004 - 0.039 in) MA
EM
LC
EC
FE
CL
MT
ACL078
Air Bleeding Procedure AT
Bleed air according to the following procedure.
Bleed air from operating cylinder. TF
1. Fill the master cylinder reservoir tank with new brake fluid.
2. Connect a transparent vinyl hose to the air bleeder.
3. Slowly depress the clutch pedal to its full stroke length and PD
release it completely. Repeat this operation several times at 2
to 3 second intervals.
4. Open the air bleeder with the clutch pedal fully depressed. FA
5. Close the air bleeder.
SCL203 6. Release the clutch pedal and wait at least 5 seconds.
7. Repeat steps 3 through 6 above until air bubbles no longer RA
appear in the brake fluid.
BR
ST
RS
BT
HA
EL
IDX
CL-7
HYDRAULIC CLUTCH CONTROL
Clutch Master Cylinder (With clutch damper)
ACL097
DISASSEMBLY AND ASSEMBLY
q Use a screwdriver to remove stopper ring while pushing push
rod into cylinder.
q When installing stopper ring, tap in lightly while pushing push
rod into cylinder.
INSPECTION
Check the following items, and replace as necessary.
q Rubbing surface of cylinder and piston, for uneven wear, rust
and damage
q Piston with piston cup, for wear and damage
q Return spring, for wear and damage
q Dust cover, for cracks, deformation and damage
q Reservoir, for deformation and damage
CL-8
HYDRAULIC CLUTCH CONTROL
Operating Cylinder GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
ACL090
PD
INSPECTION
Check the following items, and replace as necessary. FA
q Rubbing surface of cylinder and piston, for uneven wear, rust
and damage
q Piston with piston cup, for wear and damage RA
q Piston spring, for wear and damage
q Dust cover, for cracks, deformation and damage
BR
ST
RS
BT
HA
EL
IDX
CL-9
CLUTCH RELEASE MECHANISM
ACL091
REMOVAL AND INSTALLATION
q Remove release bearing.
CL145
q Install release bearing with suitable drift.
SCL705
CL-10
CLUTCH RELEASE MECHANISM
q Install retainer spring and holder spring. GI
MA
EM
LC
SCL217
INSPECTION EC
Check the following items, and replace as necessary.
q Release bearing, to see that it rolls freely and is free from
FE
noise, cracks, pitting and wear
q Release sleeve and withdrawal lever rubbing surface, for wear,
rust and damage
CL
MT
LUBRICATION AT
q Apply recommended grease to contact surface and rubbing
surface. TF
q Too much lubricant might damage clutch disc facing.
PD
FA
RA
SCL752 BR
ST
RS
BT
HA
EL
IDX
CL-11
CLUTCH RELEASE MECHANISM
WATERPROOF -- for 4WD model
q Apply recommended sealant to contact surface of transmission
case dust cover and withdrawal lever, then install dust cover
clip.
Recommended sealant: Nissan genuine part KP115-00100,
Three Bond TB1212, Loctite Part No. 51813 or equivalent.
ACL094
CL-12
CLUTCH DISC AND CLUTCH COVER
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
ACL092
PD
FA
RA
Clutch Disc
INSPECTION
Check the following items, and replace as necessary.
BR
q Clutch disc, for burns, discoloration and oil or grease leakage
q Clutch disc, for wear of facing
Wear limit of facing surface to rivet head: ST
0.3 mm (0.012 in)
RS
ACL063
q Clutch disc, for backlash of spline and runout of facing
BT
Maximum backlash of spline (at outer edge of disc):
1.0 mm (0.039 in)
Runout limit: HA
1.0 mm (0.039 in)
Distance of runout check point (from hub center):
115 mm (4.53 in) EL
IDX
ACL064
CL-13
CLUTCH DISC AND CLUTCH COVER
Clutch Disc (Cont'd)
INSTALLATION
q Apply recommended grease to contact surface of splines.
q Too much lubricant may damage clutch disc facing.
Clutch Cover and Flywheel
INSPECTION AND ADJUSTMENT
q Check clutch cover, installed on vehicle, for uneven diaphragm
spring toe height.
Uneven limit:
0.7 mm (0.028 in)
q If out of limit, adjust the height using Tool.
SCL466
FLYWHEEL INSPECTION
CAUTION:
Do not allow any magnetic materials to contact the ring gear
teeth.
q Inspect contact surface of flywheel for slight burns or discol-
oration. Clean flywheel using emery paper.
q Check flywheel runout.
Maximum allowable runout:
Refer to EM section (``Inspection'', ``CYLINDER
BLOCK'').
AEM100
INSTALLATION
q Insert Tool into clutch disc hub while installing clutch cover and
disc.
q Be careful not to allow grease to contaminate clutch facing.
q Tighten bolts in numerical order, in two steps.
First step:
: 10 - 20 N m (1.0 - 2.0 kg-m, 7 - 14 ft-lb)
Final step:
: 22 - 29 N m (2.2 - 3.0 kg-m, 16 - 22 ft-lb)
ACL079
CL-14
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications GI
CLUTCH CONTROL SYSTEM CLUTCH DISC
Unit: mm (in) MA
Type of clutch control Hydraulic
Model 240
Engine KA24DE
CLUTCH MASTER CYLINDER (with clutch EM
damper) Facing size 240 x 150 x 3.5
(Outer dia. x inner dia. x thickness) (9.45 x 5.91 x 0.138)
Unit: mm (in)
Inner diameter 15.87 (5/8)
7.75 - 8.25 LC
Thickness of disc assembly (0.3051 - 0.3248)
With load with 4904 N
CLUTCH OPERATING CYLINDER (500 kg, 1103 lb)
EC
Unit: mm (in)
Inner diameter 17.46 (11/16) CLUTCH COVER
FE
Model 240
Engine KA24DE
2WD 4904 (500, 1103) CL
Set-load N (kg, lb)
4WD 4658 (475, 1047)
MT
Inspection and Adjustment
CLUTCH PEDAL CLUTCH DISC
Unit: mm (in) Unit: mm (in) AT
Pedal height ``H''* 221 - 231 (8.70 - 9.09) Model 240
Pedal free play ``A''
9 - 16 (0.35 - 0.63)
Wear limit of facing surface to rivet head 0.3 (0.012) TF
(at pedal pad)
Runout limit of facing 1.0 (0.039)
Clearance ``C'' between pedal
Distance of runout check point
stopper bracket and clutch pedal
0.1 - 1.0 (0.004 - 0.039) (from hub center)
115 (4.53) PD
position switch (with clutch pedal
fully depressed) Maximum backlash of spline
1.0 (0.039)
*: Measured from surface of dash lower panel to pedal pad. (at outer edge of disc)
FA
CLUTCH COVER RA
Unit: mm (in)
Model 240
BR
37.5 - 39.5
Diaphragm spring height
(1.476 - 1.555)
Uneven limit of diaphragm spring
0.7 (0.028) ST
toe height
RS
BT
HA
EL
IDX
CL-15
NOTES
CL-16
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