Infiniti Car 1998-05

Driven Disc & Pressure Plate

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Transaxle
     

  6.  
  7. Insert alignment tool KV30101000 into the clutch disc hub and loosen the pressure plate bolts in small increments using a star-type pattern.

    Pressure plate and clutch disc as an assembly
     
    Release bearing by pulling the bearing retainers outward from the transaxle case
     

  8.  
  9. Inspect the clutch disc for surface wear. Measure from the friction surface to the top of the rivets. Wear limit is 0.012 in. (0.3mm). Replace clutch disc as necessary.
  10.  
  11. Inspect the contact surface of the flywheel for burns or discoloration. Check flywheel run-out. Maximum run-out is 0.0059 in. (0.15mm).
  12.  
  13. Using tools ST20050100 and ST20050010, check the pressure plate diaphragm springs. Measure from the pressure plate/flywheel mating surface to the top of the diaphragm spring. Height should be 1.201-1.280 in. (30.5-32.5mm). Replace pressure plate as necessary.
  14.  
  15. Inspect the release bearing for damage. Spin the bearing to see that it rolls freely.

    Click image to see an enlarged view

    Fig. Clutch disc and pressure plate-1998-2001 G20

  16.  

To install:

  1. Lightly lubricate the transaxle input shaft, input shaft collar, clutch lever assembly and the clutch release bearing with a lithium based grease.
    NOTE
    Keep clutch disc and all clutch components clean during installation. Do not allow grease to contact the clutch disc.

  2.  
  3. Insert alignment tool KV30101000 into the clutch disc hub. Install the clutch disc and pressure plate on the tool and torque the pressure plate bolts to 16-22 ft. lbs. (22-29 Nm) in 2-3 steps using a crisscross pattern. Remove the tool.
  4.  
  5. Install or connect the following:

    Release bearing in the transaxle. Ensure that the bearing retainer clips are fully engaged
     
    Transaxle
     
    Negative battery cable
     

  6.  
  7. If necessary, adjust clutch pedal height and free-play.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Transaxle
     

  6.  
  7. Insert alignment tool KV30101000 into the clutch disc hub and loosen the pressure plate bolts in small increments using a star-type pattern.

    Pressure plate and clutch disc as an assembly
     
    Release bearing by pulling the bearing retainers outward from the transaxle case
     

  8.  
  9. Inspect the clutch disc for surface wear. Measure from the friction surface to the top of the rivets. Wear limit is 0.012 in. (0.3mm). Replace clutch disc as necessary.
  10.  
  11. Inspect the contact surface of the flywheel for burns or discoloration. Check flywheel run-out. Maximum run-out is 0.0059 in. (0.15mm).
  12.  
  13. Using tools ST20050100 and ST20050010, check the pressure plate diaphragm springs. Measure from the pressure plate/flywheel mating surface to the top of the diaphragm spring. Height should be 1.201-1.280 in. (30.5-32.5mm). Replace pressure plate as necessary.
  14.  
  15. Inspect the release bearing for damage. Spin the bearing to see that it rolls freely.

    Click image to see an enlarged view

    Fig. Clutch disc and pressure plate-2002 G20



    Click image to see an enlarged view

    Fig. Clutch pressure plate torque sequence-2002 G20

  16.  

To install:

  1. Lightly lubricate the transaxle input shaft, input shaft collar, clutch lever assembly and the clutch release bearing with a lithium based grease.
    NOTE
    Keep clutch disc and all clutch components clean during installation. Do not allow grease to contact the clutch disc.

  2.  
  3. Insert alignment tool KV30101000 into the clutch disc hub. Install the clutch disc and pressure plate on the tool and torque the pressure plate bolts to 16-22 ft. lbs. (22-29 Nm) in 2-3 steps using a crisscross pattern. Remove the tool.
  4.  
  5. Install or connect the following:

    Release bearing in the transaxle. Ensure that the bearing retainer clips are fully engaged.
     
    Transaxle
     
    Negative battery cable
     

  6.  
  7. If necessary, adjust clutch pedal height and free-play.
  8.  



Click image to see an enlarged view

Fig. Clutch disc and pressure plate-G35

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Manual transmission assembly
     

  6.  
  7. Loosen clutch cover mounting bolts in a star pattern to avoid warping
  8.  
  9. Remove clutch cover and clutch disc
  10.  
  11. Remove throwout bearing sleeve assembly, holder spring, and throwout lever from inside clutch housing
  12.  
  13. Remove dust cover
  14.  
  15. Remove snapring from throwout lever
  16.  
  17. Remove throwout bearing from bearing sleeve using a puller
  18.  
  19. Inspect the clutch disc for surface wear. Measure from the friction surface to the top of the rivets. Wear limit is 0.012 in. (0.3mm). Replace clutch disc as necessary.
  20.  
  21. Inspect the contact surface of the flywheel for burns or discoloration. Check flywheel run-out; deflection should be less that 0.0177 inches (0.45mm). Replace flywheel if measure is exceeded.
  22.  
  23. Inspect the release bearing for damage. Turn the bearing to see that it spins freely.
  24.  

To install:

  1. Lightly lubricate the transaxle input shaft, input shaft collar, clutch lever assembly and the clutch release bearing with a lithium based grease.
    NOTE
    Keep clutch disc and all clutch components clean during installation. Do not allow grease to contact the clutch disc.

  2.  
  3. Insert an alignment tool into the clutch disc hub. Install the clutch disc and pressure plate on the tool and torque the pressure plate bolts in two passes in the order shown in diagram:

    First pass to 11 ft. lbs. (14.5 Nm)
     
    Second pass to 29 ft. lbs. (39.6 Nm)
     

  4.  
  5. Remove the tool.
  6.  
  7. Install or connect the following:

    Throwout bearing in the transmission housing; ensure that the bearing retainer clips are fully engaged
     
    Transmission
     
    Negative battery cable
     

  8.  
  9. If necessary, adjust clutch pedal height and free-play.

    Click image to see an enlarged view

    Fig. Tighten clutch cover bolts in the order shown-G35

  10.  



Click image to see an enlarged view

Fig. Clutch disc and pressure plate-I30

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transaxle fluid.
  4.  
  5. Remove or disconnect the following:

    Battery and battery bracket
     
    Air cleaner and the air flow meter
     

  6.  
  7. Raise and safely support the vehicle so there is clearance to remove the transaxle from underneath. Securely support the engine via the oil pan using a cushioning wooden block and jack.

    Transaxle from the engine and lower to the floor
     

  8.  
  9. Insert a clutch aligning bar or similar tool all the way into the clutch disc hub. This must be done so as to support the weight of the clutch disc during removal. Mark the clutch assembly-to-flywheel relationship with paint or a center punch so the clutch assembly can be assembled in the same position from which it is removed.

    Bolts in reverse order of tightening sequence, a turn at a time
     
    Pressure plate and clutch disc
     
    Release mechanism from the transaxle housing
     

  10.  
  11. Inspect the pressure plate for wear, scoring, etc., and resurface or replace, as necessary.
  12.  
  13. Measure the thickness of the clutch plate lining to the rivet heads; if the it is worn to a minimum of 0.012 in. (0.3mm), replace the clutch plate.
  14.  
  15. Inspect the release bearing and replace as necessary.
  16.  
  17. Using a dial indicator, mount it to the engine and inspect the flywheel run-out; if the run-out exceeds 0.0059 in. (0.15mm), replace it.
  18.  

To install:

  1. Apply a small amount of grease to the transaxle input shaft splines.
  2.  
  3. Install the disc on the splines and slide back and forth a few times. Remove the disc and remove excess grease on hub. Be sure no grease contacts the disc or pressure plate.
  4.  
  5. Apply lithium based molybdenum disulfide grease to the bearing sleeve inside groove, the contact point of the withdrawal lever and bearing sleeve, the contact surface of the lever ball pin and lever.
  6.  
  7. Install or connect the following:

    Release mechanism and release bearing
     
    Pressure plate and clutch disc, aligning it with a splined dummy shaft tool KV301010000
     
    Torque the pressure plate bolts in sequence as follows:
     

    1. Step 1: torque in sequence to: 7-14 ft. lbs. (10-20 Nm).
    2.  
    3. Step 2: torque in sequence to: 25-33 ft. lbs. (34-44 Nm).

      Click image to see an enlarged view

      Fig. Tighten the pressure plate bolts according to the sequence shown-I30

    4.  

  8.  
  9. Remove the dummy shaft.

    Transaxle in the correct position. Tighten the transaxle-to-engine bolts
     
    Rear and left-hand mounts
     
    Speedometer cable
     
    Electrical harness connector
     
    Clutch release cylinder
     
    Starter assembly
     

  10.  
  11. Securely support the transaxle and install the driveshafts.
  12.  
  13. Fill the transaxle with the required amount of approved fluid.

    Air flow meter and the air cleaner
     
    Battery and battery bracket
     

  14.  
  15. Road test the vehicle for proper shift operation
  16.  

 
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