Nissan Frontier D22. Instruction — part 201
PREPARATION
CL-3
D
E
F
G
H
I
J
K
L
M
A
B
CL
PREPARATION
PFP:00002
Special Service Tools
ECS007GM
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Commercial Service Tools
ECS007GN
Tool number
(Kent-Moore No.)
Tool name
Description
ST20630000
(J26366)
Clutch aligning bar
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)
ST20050240
(
—
)
Diaphragm spring adjusting wrench
Adjusting unevenness of diaphragm spring of
clutch cover
a: 150 mm (5.91 in)
b: 25 mm (0.98 in)
NT405
NT404
Tool name
Description
1 Flare nut crowfoot
2 Torque wrench
Removing and installing clutch piping
a: 10 mm (0.39 in)
Bearing puller
Removing release bearing
Bearing drift
Installing release bearing
a: 52 mm (2.05 in) dia.
b: 45 mm (1.77 in) dia.
NT360
NT077
NT474
CL-4
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
NVH Troubleshooting Chart
ECS007GO
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.
Reference page
(
KA24DE)
,
(VG3
3
E
& VG33ER)
SUSPECTED PARTS
(Possible cause)
C
L
U
T
C
H
PED
AL
(
In
s
pec
ti
on
an
d
Adj
u
s
tm
ent
)
CL
UTCH L
INE
(A
ir in
l
in
e
)
MAST
ER
CYL
INDER PI
ST
ON CUP
(Da
m
a
g
e
d
)
OPE
R
A
T
ING C
Y
L
INDER PIST
ON
CUP (
D
a
m
a
g
e
d
)
E
N
GINE M
O
UNTING
(L
o
o
s
e
)
REL
EASE BEARI
N
G (
W
or
n,
dir
ty or
d
a
m
aged
)
CL
UTCH DISC (Ou
t o
f
tr
u
e
)
CL
UTCH DISC (Ru
n
o
u
t is
e
x
c
e
s
s
iv
e
)
CL
UTCH DISC (L
in
in
g
b
ro
k
e
n
)
CL
UTCH DISC (Dir
ty
o
r
b
u
rn
e
d
)
CL
UTCH DISC (Oil
y
)
CL
UTCH DISC (W
o
rn
o
u
t)
C
L
U
T
C
H
D
ISC
(
H
ar
dene
d)
C
L
U
T
C
H
D
ISC
(
Lac
k
of
sp
line
gr
eas
e)
DIAPHRAGM S
P
RI
NG
(D
a
m
a
g
e
d
)
DIAPHRAGM
S
P
RI
NG (
O
u
t o
f ti
p
a
lig
n
m
e
n
t)
P
R
E
SSURE PL
A
T
E (
D
is
to
rt
io
n)
F
L
YW
HEEL
(
D
is
to
rt
io
n)
Symptom
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 dis-
engage
1
2
3
4
5
5
5
5
5
5
6
6
7
CLUTCH SYSTEM — HYDRAULIC TYPE
CL-5
D
E
F
G
H
I
J
K
L
M
A
B
CL
CLUTCH SYSTEM — HYDRAULIC TYPE
PFP:30502
Components
ECS007GP
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 clutch switch
10. Pedal stopper bolt (without ASCD)
11. Snap pin
12. Assist spring
13. Clutch disc
14. Clutch cover
15. Release bearing
16. Release bearing sleeve
17. Withdrawal lever
18. Operating cylinder
19. Air bleeder
20. Clutch damper (not serviceable)
21. Flare nut
22. Bushing
WCL044
CL-6
CLUTCH SYSTEM — HYDRAULIC TYPE
Inspection and Adjustment
ECS007GQ
CLUTCH PEDAL INSPECTION AND ADJUSTMENT
1.
Check to see if the clutch pedal clevis pin floats freely in the bore
of the clutch pedal. It should not be bound by the clevis or clutch
pedal.
a.
If the pin is not free, check that the ASCD switch or pedal stop-
per bolt is not applying pressure to the clutch pedal causing the
pin to bind. To adjust, loosen the ASCD switch or pedal stopper
bolt lock nut and turn the ASCD switch or pedal stopper bolt.
b.
Tighten the lock nut.
c.
Verify that the clutch pedal clevis pin floats freely in the bore of
the clutch pedal. It should not be bound by the clevis or clutch
pedal.
d.
If the pin is still not free, remove the pin and check for deforma-
tion or damage. Replace the pin if necessary. Leave the pin
removed for step 2.
2.
Check the clutch pedal stroke for free range of movement.
a.
With the clutch pedal clevis pin removed, instructionly move the
pedal up and down to determine if it moves freely.
b.
If any sticking is noted, replace the related parts (clutch pedal,
pedal bracket, assist spring, bushing, etc.). Reassemble the
pedal and re-verify that the clevis pin floats freely in the bore of
the pedal.
3.
Adjust the clearance “C” while fully depressing the clutch pedal
(with the clutch interlock switch) as shown.
4.
Check the clutch hydraulic system components (clutch master
cylinder, clutch operating cylinder, Clutch withdrawal lever,
clutch release bearing, etc.) for sticking or binding.
a.
If any sticking or binding is noted, repair or replace the related
parts as necessary.
b.
If the hydraulic system was necessary, bleed the clutch hydrau-
lic system. Refer to
NOTE:
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 of the air from the system.
BLEEDING PROCEDURE
CAUTION:
Carefully monitor the fluid level at the clutch master cylinder during the bleeding operation.
NOTE:
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 of the air from the system.
1.
Top off the clutch master cylinder reservoir with the recommended brake fluid "DOT 3".
WCIA0146E
Clearance "C"
: 0.1 - 1.0 mm (0.004 - 0.039 in)
SCL800
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