Nissan Xterra Clutch CL 2000 Owner's Manual

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Page 1

CLUTCH

CONTENTS

PRECAUTIONS ...............................................................2

Precautions..................................................................2

PREPARATION ...............................................................3

Special Service Tools ..................................................3

Commercial Service Tools...........................................3

NOISE, VIBRATION AND HARSHNESS (NVH)

TROUBLESHOOTING.....................................................4

NVH Troubleshooting Chart.........................................4

CLUTCH

CLUTCH SYSTEM - HYDRAULIC TYPE........................5

Components.................................................................5

Inspection and Adjustment ..........................................6

ADJUSTING CLUTCH PEDAL AIR BLEEDING PROCEDURE

CLUTCH MASTER CYLINDER.......................................8

Components.................................................................8

Disassembly and Assembly.........................................8

Inspection.....................................................................8

OPERATING CYLINDER.................................................9

Components.................................................................9

Inspection.....................................................................9

...................................................................4

....................................6

....................................7

SECTION

CLUTCH RELEASE MECHANISM...............................10

Components...............................................................10

Removal and Installation...........................................10

Inspection...................................................................11

Lubrication .................................................................11

Waterproof - for 4WD Model.....................................11

CLUTCH DISC, CLUTCH COVER AND

FLYWHEEL....................................................................12

Components...............................................................12

Inspection and Adjustment ........................................12

CLUTCH DISC CLUTCH COVER AND FLYWHEEL FLYWHEEL INSPECTION

Installation..................................................................13

SERVICE DATA AND SPECIFICATIONS (SDS).........14

Clutch Control System...............................................14

Clutch Master Cylinder (with clutch damper)............14

Clutch Operating Cylinder .........................................14

Clutch Disc.................................................................14

Clutch Cover..............................................................14

Clutch Pedal ..............................................................14

.........................................................12

...........................13

........................................13

IDX

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Precautions

PRECAUTIONS

SBR686C

Precautions

NGCL0001

I Recommended fluid is brake fluid “DOT 3”. I Never reuse drained brake fluid. I Be careful not to splash brake fluid on painted areas. I When removing and installing clutch piping, use Tool. I Use new brake fluid to clean or wash all parts of master

cylinder, operating cylinder, and clutch damper.

I Never use mineral oils such as gasoline or kerosene. It will

ruin the rubber parts of the hydraulic system.

WARNING:

After cleaning the clutch disc, wipe it with a dust collector. Do not use compressed air.

CL-2

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PREPARATION

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.) Tool name

ST20630000 (J26366) Clutch aligning bar

ST20050240 (—) Diaphragm spring adjusting wrench

Description

Installing clutch cover and clutch disc

a: 15.9 mm (0.626 in) dia. b: 22.8 mm (0.898 in) dia. c: 55 mm (2.17 in)

NT405

Adjusting unevenness of diaphragm spring of clutch cover

a: 150 mm (5.91 in) b: 25 mm (0.98 in)

NT404

Commercial Service Tools

Tool name Description 1 Flare nut crowfoot

2 Torque wrench

Removing and installing clutch piping

a: 10 mm (0.39 in)

NGCL0002

NGCL0003

Bearing puller

Bearing drift

NT360

NT077

NT474

Removing release bearing

Installing release bearing

a: 52 mm (2.05 in) dia. b: 45 mm (1.77 in) dia.

CL-3

IDX

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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

NGCL0027

NVH Troubleshooting Chart

NGCL0027S01

Use the chart below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, repair or replace these parts.

CLUTCH

Reference page

SUSPECTED PARTS (Possible cause)

CL-6

CL-7

CL-8

CL-9

EM-41

EM-100

CL-10

CL-12

CL-13

NGCL0027S0101

CL-13

Symptom

CLUTCH PEDAL (Free play out of adjustment)

CLUTCH LINE (Air in line)

MASTER CYLINDER PISTON CUP (Damaged)

OPERATING CYLINDER PISTON CUP (Damaged)

ENGINE MOUNTING (Loose)

RELEASE BEARING (Worn, dirty or damaged)

CLUTCH DISC (Out of true)

CLUTCH DISC (Runout is excessive)

CLUTCH DISC (Lining broken)

CLUTCH DISC (Dirty or burned)

CLUTCH DISC (Oily)

CLUTCH DISC (Worn out)

CLUTCH DISC (Hardened)

CLUTCH DISC (Lack of spline grease)

DIAPHRAGM SPRING (Damaged)

DIAPHRAGM SPRING (Out of tip alignment)

PRESSURE PLATE (Distortion)

Clutch grabs/chatters 1 2 2 2 2 2

Clutch pedal spongy 1 2 2

Clutch noisy 1

Clutch slips 1 2 2 3 4 5

Clutch does not disengage 1234 55555 5667

FLYWHEEL (Distortion)

CL-4

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CLUTCH SYSTEM — HYDRAULIC TYPE

Components

NGCL0004

1. Clutch pedal bracket

2. Clutch interlock switch

3. Clutch master cylinder

4. Fulcrum pin

5. Bushing

6. Clevis pin

7. Clutch pedal

8. Lock nut

9. ASCD cancel switch

10. Pedal stopper

11. Snap pin

12. Assist spring

13. Clutch disc

14. Clutch cover

15. Release bearing

16. Release bearing sleeve

17. Withdrawal lever

18. Dust boot

19. Operating cylinder

20. Air bleeder

21. Clutch damper

22. Flare nut

23. Bushing

ACL106

CL-5

IDX

Page 6

Inspection and Adjustment

CLUTCH SYSTEM — HYDRAULIC TYPE

ACL107

Inspection and Adjustment

ADJUSTING CLUTCH PEDAL

NGCL0005

NGCL0005S01

1. Adjust pedal height with pedal stopper orASCD cancel switch.

Pedal height “H”:

KA24DE: 221 – 231 mm (8.70 – 9.09 in) VG33E: 227 – 237 mm (8.94 – 9.33 in)

2. Adjust pedal free play with master cylinder push rod. Then tighten lock nut.

Pedal free play (measured at pedal pad) “A”:

9 - 16 mm (0.35 - 0.63 in)

Pedal free play means the following total measured at position of pedal pad:

I Play due to clevis pin, clevis pin hole in clutch pedal and

master cylinder.

3. Make sure that clevis pin can rotate smoothly. If not, readjust pedal free play with master cylinder push rod.

ACL104

CL-6

Page 7

CLUTCH SYSTEM — HYDRAULIC TYPE

Inspection and Adjustment (Cont’d)

ACL103

SCL203-A

— Models with Clutch Interlock System —

1. Adjust clearance “C” shown in the figure while fully depressing clutch pedal.

Clearance C:

0.1 - 1.0 mm (0.004 - 0.039 in)

AIR BLEEDING PROCEDURE

Bleed air according to the following procedure. Bleed air from operating cylinder.

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 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.

5) Close the air bleeder.

6) Release the clutch pedal and wait at least 5 seconds.

7) Repeat steps 3 through 6 above until air bubbles no longer appear in the brake fluid

NGCL0005S0101

NGCL0005S02

CL-7

IDX

Page 8

Components

CLUTCH MASTER CYLINDER

Components

Disassembly and Assembly

NGCL0006

ACL108

NGCL0007

I Use a screwdriver to remove stopper ring while pushing push

rod into cylinder.

I When installing stopper ring, tap in lightly while pushing push

rod into cylinder.

Inspection

NGCL0008

Check the following items, and replace if necessary. I Rubbing surface of cylinder and piston, for uneven wear, rust,

or damage

I Piston with piston cup, for wear or damage I Return spring, for wear or damage I Dust cover, for cracks, deformation, or damage I Reservoir, for deformation or damage

CL-8

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OPERATING CYLINDER

Components

Inspection

Check the following items, and replace if necessary. I Rubbing surface of cylinder and piston, for uneven wear, rust,

or damage

I Piston with piston cup, for wear or damage I Piston spring, for wear or damage I Dust cover, for cracks, deformation, or damage

NGCL0009

ACL109

NGCL0010

CL-9

IDX

Page 10

Components

CLUTCH RELEASE MECHANISM

Components

Removal and Installation

I Remove release bearing.

NGCL0013

ACL110

NGCL0014

CL145

SCL705

SCL217

I Install release bearing with suitable drift.

I Install retainer spring and holder spring.

CL-10

Page 11

CLUTCH RELEASE MECHANISM

Inspection

Check the following items, and replace if necessary. I Release bearing, to see that it rolls freely and is free from

noise, cracks, pitting, or wear.

I Release sleeve and withdrawal lever rubbing surface, for wear,

rust, or damage

Lubrication

I Apply recommended grease to contact surface and rubbing

surface.

I Too much lubricant might damage clutch disc facing dam-

age.

NGCL0015

ACL105

NGCL0016

Waterproof — for 4WD Model

I Apply recommended sealant to contact surface of dust cover

to transmission case and withdrawal lever and then install dust cover clip.

Recommended sealant: Nissan genuine part (KP115-

00100), Three Bond TB1212, Loctite Part Number 51813, or equivalent

NGCL0017

ACL094

IDX

CL-11

Page 12

Components

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

Components

NGCL0018

ACL063

ACL100

Inspection and Adjustment

CLUTCH DISC

NGCL0019

NGCL0019S01

Check the following items, and replace if necessary.

I Clutch disc, for burns, discoloration, oil, or grease leakage I Clutch disc, for wear of facing

Wear limit of facing surface to rivet head:

0.3 mm (0.012 in)

I Clutch disc, for backlash of spline and runout of facing

Maximum backlash of spline (at outer edge of disc):

1.0 mm (0.039 in)

Runout limit:

1.0 mm (0.039 in)

Distance of runout check point (from hub center):

Model 240: 115 mm (4.53 in) Model 250: 120 mm (4.72 in)

ACL064

CL-12

Page 13

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

Inspection and Adjustment (Cont’d)

SCL466

AEM100

ACL079

CLUTCH COVER AND FLYWHEEL

쐌 Check clutch cover, installed on vehicle, for uneven diaphragm

spring toe height.

Uneven limit:

KA24DE: 0.7 mm (0.028 in) VG33E: 0.5 mm (0.0020 in)

쐌 If out of limit, adjust the height with Tool.

FLYWHEEL INSPECTION

CAUTION:

Do not allow any magnetic materials to contact the ring gear teeth.

쐌 Inspect contact surface of flywheel for slight burns or discol-

oration. Clean flywheel with emery paper.

쐌 Check flywheel runout.

Maximum allowable runout:

Refer to EM-52 (KA24DE engine) or EM-110 (VG33E engine), “Inspection”, “CYLINDER BLOCK”.

Installation

쐌 Apply recommended grease to contact surface of splines. 쐌 Too much lubricant may damage clutch disc facing. 쐌 Insert Tool into clutch disc hub when installing clutch cover and

disc.

쐌 Be careful not to allow grease to contaminate clutch facing. 쐌 Tighten bolts in numerical order, in two steps.

First step:

: 10 - 20 N·m (1.0 - 2.0 kg-m,7-14ft-lb)

Final step:

: 22 - 29 N·m (2.2 - 3.0 kg-m, 16 - 22 ft-lb)

NGCL0019S02

NGCL0019S03

NGCL0020

CL-13

IDX

Page 14

Clutch Control System

SERVICE DATA AND SPECIFICATIONS (SDS)

Clutch Control System

Type of clutch control Hydraulic

Clutch Master Cylinder (with clutch damper)

Inner diameter 15.87 mm (5/8 in)

Clutch Operating Cylinder

Inner diameter 19.05 mm (3/4 in)

Clutch Disc

Model 250 Engine VG33E Facing size

(Outer dia. x inner dia. x thickness)

Thickness of disc assembly with load

Wear limit of facing surface to rivet head 0.3 (0.012) Runout limit of facing 1.0 (0.039) Distance of runout check point (from hub center) 120 (4.72) Maximum backlash of spline (at outer edge of disc) 1.0 (0.039)

250 x 160 x 3.5

(9.84 x 6.30 x 0.138)

8.1 - 8.5 (0.3189 - 0.3346)

with 6,473 N (660 kg, 1,455 lb)

NGCL0028

NGCL0021

NGCL0022

NGCL0023

Unit: mm (in)

Clutch Cover

Engine VG33E Model 250

Set-load

Diaphragm spring height 36.5 - 38.5 (1.437 - 1.516) Uneven limit of diaphragm spring toe height 0.5 (0.020)

2WD 4,658 N (475 kg, 1,047 lb) 4WD 4,658 N (475 kg, 1,047 lb)

Clutch Pedal

Engine VG33E Pedal height “H”* 227 - 237 (8.94 - 9.33) Pedal free play “A” (at pedal pad) 7 - 14 (0.27 - 0.55) Clearance “C” between pedal stopper bracket and clutch pedal position

switch (with clutch pedal fully depressed.)

*: Measured from surface of dash lower panel to pedal pad.

0.1 - 1.0 (0.004 - 0.039)

NGCL0024

Unit: mm (in)

NGCL0025

Unit: mm (in)

CL-14