Nissan PULSAR N13 Series / ASTRA LD Series. Manual — part 30

121

CLUTCH

SPECIFICATIONS

Type. . . . . . . . . . . . ... Single dry plate

Operation. . . . . . . . . . . . ...Mechanical

Pressure plate type. . . . . . . . . Diaphragm

Release bearing type. . . . . ...Prelubricated ball

Driven plate:

Outside diameter . . . . . . . . . 215 mm

Rivet depth limit . . . . . . . . . 0.3 mm

Runout limit . . . . . . . . . . .0.5 mm

Maximum spline backlash . . . . ...0.7 mm

Pressure plate:

Diaphragm spring height

(installed) . . . . . . . . . .. 30.5-32.5 mm

Spring finger variation limit. . . . . .0.5 mm

Clutch pedal:

Height . . . . . . . . . . . ..175-185 mm

Free play . . . . . . . . . ... 12.5-17.5 mm

Release lever free play. . . . . . . 2.5-3.5 mm

Flywheel machining limit . . . . . . . ...0.3 mm

TORQUE WRENCH SETTINGS

Pressure plate bolts. . . . . . . . . . .. 29 Nm

Pedal pivot pin nut . . . . . . . . . . . 22 Nm

Cable locknut . . . . . . . . . . . . . 4 Nm

Lower clutch housing to engine bolts. . . .. 21 Nm

Centre and upper clutch housing

to engine bolts. . . . . . . . . . . . .. 49 Nm

1. CLUTCH TROUBLE SHOOTING

CLUTCH SLIPPING

(!) Worn driven plate facing: Check and renew

the clutch driven plate.

(2) Insufficient clutch pedal free play: Check and

adjust the clutch pedal free play. Ensure that the
release lever free play is correct.

(3) Weak or broken pressure plate diaphragm

spring: Check and renew the pressure plate assembly.

(4) Worn or scored flywheel: Machine or renew

the flywheel.

Worn or scored pressure plate face: Renew the

pressure plate assembly.

Renew the clutch driven plate if the friction material is

worn down to, or is within 0.3 mm of the rivets.

NOTE: In most cases clutch slippage is first
evident by a marked increase in engine revs,
for no apparent reason, when pulling up a
steep hill. The clutch condition can be
positively diagnosed as follows: With the
handbrake firmly applied, and the rear
wheels chocked, select top gear and release
the clutch with the engine running at ap-
proximately 2 000 rpm. Clutch slippage is
evident if the engine does not stall. Make the
test as quickly as possible to prevent any
further clutch damage.

CLUTCH SHUDDER

(1) Oil on the driven plate facings: Renew the

clutch driven plate. Investigate and rectify the source
of the oil leak.

(2) Scored pressure plate or flywheel face: Re-

new the pressure plate assembly or machine the
flywheel.

(3) Loose or damaged driven plate hub: Check

and renew the clutch driven plate.

(4) Loose driven plate facings: Renew the clutch

driven plate.

(5) Cracked pressure plate face: Renew the pres-

sure plate assembly.

122

Clutch

Check the engine mountings for damage and deterio-

ration.

NOTE: Clutch shudder is usually most
evident when reversing up an incline. As
loose or damaged engine mountings are a
cause for clutch shudder, thoroughly check
the engine mounting rubbers and mounting
hardware for damage or looseness before
removing the clutch for inspection.

CLUTCH GRAB

(1) Oil soaked driven plate facings: Renew the

clutch driven plate. Investigate and rectify the source
of the oil leak.

(2) Cracked pressure plate face: Renew the pres-

sure plate assembly.

(3) Loose or broken engine mountings: Check

and renew the engine mountings as necessary.

(4) Binding release mechanism: Check the oper-

ation of the release mechanism.

NOTE: Visually check the operation of the
cable actuated release mechanism. Check
the inner cable for fraying and jamming in
the outer cable.

INSUFFICIENT CLUTCH RELEASE

(1) Stretched, frayed or broken clutch cable:

Check and renew the clutch cable.

(2) Worn or damaged release mechanism: Check

and renew components as necessary.

(3) Insufficient pedal height: Check and adjust

the pedal height.

(4) Warped clutch driven plate: Renew the

clutch driven plate.

(5) Excessive clutch release lever free play:

Check and adjust the release lever free play to
Specifications.

NOTE: Visually check that the clutch cable
operates the release lever before removing
the clutch for inspection.

RELEASE BEARING NOISE

(1) Dry or worn release bearing: Check and

renew the release bearing.

(2) Damaged pressure plate diaphragm spring;

Check and renew the pressure plate assembly.

NOTE: Lightly depress the clutch pedal with
the engine running to check for release
bearing noise. If the release bearing is faulty
and has to be renewed, always check the
other clutch components.

Check the diaphragm spring fingers for scoring and

damage.

2. DESCRIPTION

The clutch consists of a single, dry, driven plate

assembly, splined to slide on the transaxle input shaft.
A diaphragm spring type pressure plate assembly is
bolted to the engine flywheel.

The driven plate is sandwiched between the

pressure plate and the flywheel and transmits the
drive from the engine to the transaxle.

Cushion rubbers are interposed between the hub

of the driven plate assembly and the plate friction
surfaces in order to cushion the drive.

The release mechanism is actuated by the clutch

pedal through a cable to the release lever and bearing.

Operation of the clutch pedal moves the release

lever which pushes the release bearing into contact
with the diaphragm spring fingers, forcing the dia-
phragm centre towards the flywheel. When the outer
edge of the diaphragm deflects, the clutch is caused to
disengage.

Clutch pedal free play is adjusted at the release

lever end of the clutch cable.

Clutch pedal height is adjusted at the pedal stop

on the pedal mounting bracket located under the
dashboard.

Clutch

123

3. CLUTCH UNIT AND RELEASE

MECHANISM

Special Equipment Required:

To Install — Clutch aligning tool

TO REMOVE

(1) Remove the transaxle from the vehicle as

described in the Manual Transaxle section.

(2) Mark the pressure plate cover in relation to

the flywheel to ensure installation to the original
location.

(3) Progressively loosen and remove the pressure

plate assembly retaining bolts working in a diagonal
sequence across the assembly.

(4) Remove the pressure plate and driven plate

assemblies from the flywheel. Note the installed
direction of the driven plate to aid assembly.

(5) Disengage the clips retaining the release

bearing carrier to the release fork and slide the release
bearing assembly out of the clutch housing. Note the
installed position of the retaining clips to aid assem-
bly.

(6) Align the release fork retaining pins with the

slots in the clutch housing and remove the pins using
a pin punch.

(7) Remove the release lever and shaft and

withdraw the release fork and return spring from the
clutch housing.

TO CHECK AND INSPECT

(1) Check the driven plate facings. Renew the

driven plate if the facings are worn down to within
0.3 mm of the rivet heads or are gummy and oil
soaked.

(2) Check the driven plate hub cushion rubbers

for deterioration and damage. Renew the driven plate
if the hub is damaged.

(3) Mount the driven plate on the transaxle

input shaft and measure the spline backlash at the
outer edge of the driven plate. Renew the driven plate
if the spline backlash is beyond Specifications.

(4)

Check the pressure plate assembly for wear

on the diaphragm spring fingers, cracked diaphragm
spring and a cracked or distorted cover. Check that
the pressure plate face is not badly scored.

(5) Check the flywheel face for heat cracks, burn

marks and scoring. Renew the flywheel if it is badly
scored.

NOTE: Slight glazing or burn marks on the
pressure plate or flywheel faces can be
corrected using emery paper. Minor scoring
on the flywheel face may be corrected by
machining the flywheel.

(6) Rotate the release bearing by hand and check

for noise or roughness. Renew the bearing and carrier
as an assembly if faults are found.

(7) Check the release lever and shaft for wear

and damage. Renew as necessary.

(8) Check the release shaft bushes and seal for

wear or damage. Renew as necessary.

(9) Check the release fork for wear and the

return spring for fatigue. Renew as necessary.

TO INSTAL

(1) Sparingly apply lithium base molybdenum

disulphide grease to the transaxle input shaft splines,
release bearing carrier bore and rear contact surfaces,
release shaft bushes and release fork contact surfaces.
Slide the driven plate onto the transaxle input shaft
and remove the excess grease from the splines.

(2) Install the release shaft to the clutch housing,

return spring and release fork. Install the retaining pins

Dismantled view of the flywheel, driven plate and

clutch pressure plate.

Dismantled view of the clutch release components

.

124

Clutch

Illustration showing the clutch aligning tool. The tool
can be readily fabricated from a length of round section
wood or metal. Dimension A = diameter of the ma-
chined section of the crankshaft. Dimension B - inside
diameter of the driven plate hub.

to the release fork ensuring that the return spring is
correctly anchored.

(3) Install the release bearing to the clutch hous-

ing and install the clips retaining the release bearing
carrier to the release fork.

(4) Install the driven plate to the flywheel in the

direction noted on removal. Install the aligning tool to
hold the driven plate in position.

NOTE: Some driven plates are marked
Flywheel side to indicate the correct in-
stalled direction.

(5) Install the pressure plate to the flywheel in the

position marked on removal.

(6) Ensure that the driven plate is correctly

centered and install the pressure plate retaining
bolts.
Tighten the bolts progressively in a diagonal sequence
to the specified torque.

(7) Install the transaxle to the vehicle as de-

scribed in the Manual Transaxle section.

(8) Adjust the clutch pedal height and free play

as described under the Adjustments heading later in
this section.

4. CLUTCH PEDAL

TO REMOVE AND INSTAL

(1) Working in the engine compartment, loosen

the adjusting nut and disconnect the inner clutch
cable from the clutch release lever at the clutch
housing.

(2) Working inside the vehicle, release the inner

clutch cable from the top of the clutch pedal.

(3) Remove the nut from the end of the clutch

pedal pivot pin.

(4) Note the installed position of the clutch

pedal return spring and remove the pivot pin from the
clutch pedal.

(5) Remove the clutch pedal from the vehicle

and remove the bush from the clutch pedal.

(6) Examine the clutch pedal and the bush for

bend, cracks, wear and damage. Examine the return

Installed view of the clutch pedal

.

spring for cracks and fatigue. Renew parts as neces-
sary.

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Lubricate the hook on the top of the clutch

pedal and the pivot pin and bush with lithium base
molybdenum disulphide grease.

(2) Install the return spring to the position noted

on removal.

(3) If necessary, adjust the pedal height and free

play as described under the Adjustments heading later
in this section.

5. CLUTCH CABLE

TO REMOVE AND INSTAL

(1) Working in the engine compartment, loosen

the adjusting nut and disconnect the inner clutch
cable from the clutch release lever at the clutch
housing.

(2) Release the outer clutch cable retaining nut

and slide the outer cable out of the slot in the
mounting bracket.

View of the clutch cable assembly.