Nissan Frontier. Manual - part 207

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TRANSMISSION & DRIVELINE

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SECTION 

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CONTENTS

CLUTCH

SYMPTOM DIAGNOSIS  ...............................

3

NOISE, VIBRATION AND HARSHNESS 
(NVH) TROUBLESHOOTING  .............................

3

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

3

PRECAUTION ...............................................

4

PRECAUTIONS ...................................................

4

Precaution for Supplemental Restraint System 
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...................................................................

4

Service Notice or Precautions ...................................

4

PREPARATION ............................................

5

PREPARATION ...................................................

5

Special Service Tool  .................................................

5

Commercial Service Tool  ..........................................

5

PERIODIC MAINTENANCE ..........................

7

CLUTCH PEDAL  .................................................

7

On-Vehicle Inspection and Adjustment  .....................

7

CLUTCH FLUID ...................................................

8

Bleeding ....................................................................

8

REMOVAL AND INSTALLATION ................

9

CLUTCH PEDAL  .................................................

9

Exploded View  ..........................................................

9

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

9

Inspection ..................................................................

9

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

10

Exploded View  ........................................................

10

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

10

CLUTCH RESERVOIR  .......................................

11

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

11

OPERATING CYLINDER  ...................................

12

Exploded View .........................................................

12

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

12

CLUTCH PIPING ...............................................

13

Exploded View .........................................................

13

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

13

UNIT REMOVAL AND INSTALLATION ......

14

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

14

5M/T ...........................................................................

14

5M/T : Exploded View ..............................................

14

5M/T : Removal and Installation ..............................

14

5M/T : Inspection  .....................................................

15

6M/T ...........................................................................

15

6M/T : Exploded View ..............................................

16

6M/T : Removal and Installation ..............................

16

6M/T : Inspection  .....................................................

17

CLUTCH DISC, CLUTCH COVER ....................

19

5M/T ...........................................................................

19

5M/T : Exploded View ..............................................

19

5M/T : Removal and Installation ..............................

19

5M/T : Inspection after Removal ..............................

20

5M/T : Adjustment after Installation  .........................

21

6M/T ...........................................................................

21

6M/T : Exploded View ..............................................

21

6M/T : Removal and Installation ..............................

22

6M/T : Inspection after Removal ..............................

22

6M/T : Adjustment after Installation  .........................

23

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

25

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

25

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

25

Clutch Master Cylinder  ............................................

25

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

25

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Clutch Disc  .............................................................

25

Clutch Cover ...........................................................

25

Clutch Pedal ............................................................

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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

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< SYMPTOM DIAGNOSIS >

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SYMPTOM DIAGNOSIS

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

INFOID:0000000009478198

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-

tion. If necessary, repair or replace these parts.

CLUTCH

Reference page

CL-7

CL-8

BR

-4

3

CL-12

EM-77

 (QR25D

E

),

EM-216

 (VQ

40DE

)

CL-14

 (5M/T),

CL-16

 (6 M/T

)

CL-19

 (5M/T),

CL-21

 (6M/

T)

EM-91

 (QR25D

E

),

EM-230

 (VQ

40DE

)

SUSPECTED PARTS (Possible cause)

CLUTCH PE

DAL (F

ree

 pl

ay

 ou

t o

f a

dj

us

tm

ent

)

CLUTCH LINE (A

ir in line)

MAS

T

ER CYLINDER PIS

T

ON CUP (Damaged)

OPERA

T

ING CYLI

ND

E

R

 PIST

ON CUP (Damaged)

ENGINE MOU

NTING (Loose)

RELEA

SE BEA

RI

NG 

(W

o

rn,

 di

rty 

or d

am

ag

ed

)

CLUTCH DIS

C

 (Out 

of 

true)

CLUTCH DIS

C

 (Runou

t i

s ex

ce

ss

iv

e)

CLUTCH DIS

C

 (Lining 

broken)

CLUTCH DIS

C

 (Dirty or burned)

CLUTCH DIS

C

 (Oily)

CLUTCH DIS

C

 (W

orn 

out)

CLUTCH DIS

C

 (Hardened)

CLUTCH DIS

C (Lack of

 s

pli

ne

 gre

as

e

)

DI

APHRAGM SPRI

N

G (Dam

ag

ed

)

DIAPHRAGM

 SPRING (Out

 of

 tip

 a

lig

nm

en

t)

PRESSURE P

LA

T

E (Di

storti

on)

FL

YWHEE

L (Distortion)

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  disengage

1

2

3

4

5

5

5

5

5

5

6

6

7

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< PRECAUTION >

PRECAUTIONS

PRECAUTION

PRECAUTIONS

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT 
PRE-TENSIONER"

INFOID:0000000010138339

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along

with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain

types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS

system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front

air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.

Information necessary to service the system safely is included in the SR and SB section of this Service Man-

ual.

WARNING:

• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in

the event of a collision which would result in air bag inflation, all maintenance must be performed by

an authorized NISSAN/INFINITI dealer.

• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal

injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag

Module, see the SR section.

• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this

Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-

ness connectors.

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

WARNING:

• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni-

tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a

hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing

serious injury.

• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the

battery and wait at least three minutes before performing any service.

Service Notice or Precautions

INFOID:0000000009478200

• Always use recommended fluid. Refer to 

MA-16, "FOR USA AND CANADA : Fluids and Lubricants"

.

• Do not reuse drained fluid.

• Be careful not to splash fluid on painted areas.

• When removing and installing clutch piping, use tool.

• Use new fluid to clean or wash all parts of master cylinder.

• Do not use mineral oils such as gasoline or kerosene. It will ruin

the rubber parts of the hydraulic system.

WARNING:

After cleaning clutch disc, wipe it with a dust collector. Do not

use compressed air.

SBR686C