Nissan 240SX/Altima 1993-1998 Repair Guide

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16 and 17



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Fig. Fig. 1: Exploded view of a manual transaxle's clutch release mechanism, showing the lubrication points



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Fig. Fig. 2: Exploded view of a manual transmission's clutch release mechanism, showing the lubrication points



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Fig. Fig. 3: Typical clutch alignment tool; note how the splines match the transmission's input shaft



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Fig. Fig. 4: Loosen and remove the clutch and pressure plate bolts evenly, a little at a time ...



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Fig. Fig. 5: ... then carefully remove the clutch and pressure plate assembly from the driveplate



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Fig. Fig. 6: Check across the driveplate surface; it should be flat



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Fig. Fig. 7: If necessary, lock the driveplate in place and remove the retaining bolts ...



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Fig. Fig. 8: ... then remove the driveplate from the crankshaft in order to replace it or have it machined



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Fig. Fig. 9: Upon installation, it is usually a good idea to apply a threadlocking compound to the driveplate bolts



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Fig. Fig. 10: Check the pressure plate for excessive wear



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Fig. Fig. 11: Be sure that the driveplate surface is clean, before installing the clutch



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Fig. Fig. 12: Install a clutch alignment arbor, to align the clutch assembly during installation



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Fig. Fig. 13: Clutch plate and pressure plate installed with the alignment arbor in place



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Fig. Fig. 14: The pressure plate-to-driveplate bolt holes should align



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Fig. Fig. 15: You may want to use a threadlocking compound on the clutch assembly bolts



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Fig. Fig. 16: Install the clutch assembly bolts and tighten in steps, using an X pattern



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Fig. Fig. 17: Be sure to use a torque wrench to tighten all bolts

  1. Remove the transmission/transaxle from the engine.
  2.  
  3. Insert a clutch alignment tool all the way into the clutch disc hub. This must be done to support the weight of the clutch disc during removal.
  4.  
  5. Matchmark the clutch assembly-to-driveplate relationship for installation reference.
  6.  
  7. Loosen the pressure plate bolts in sequence, a turn at a time.
  8.  
  9. Remove the pressure plate and clutch disc.
  10.  

To install:
  1. Inspect all components and replace as necessary.
  2.  

The clutch cover and pressure plate are balanced as an assembly. If replacement of either part becomes necessary, replace all components as an assembly (clutch disc, pressure plate and release bearing).

  1. Lubricate the transaxle/transmission splines with grease.
  2.  
  3. Install the disc on the splines and slide it back and forth a few times. Remove the disc and remove any excess grease.
  4.  

Be sure no grease contacts the disc or pressure plate.

  1. Remove the release mechanism from the transmission/transaxle housing.
  2.  
  3. Lubricate the bearing sleeve inside groove, the contact point of the withdrawal lever and bearing sleeve, the contact surface of the lever ball pin and the lever with a lithium based molybdenum disulfide grease.
  4.  
  5. Install the clutch disc on the alignment tool.
  6.  
  7. Install the pressure plate and evenly tighten the bolts to 2-8 ft. lbs. (8-15 Nm).
  8.  
  9. Remove the clutch alignment tool.
  10.  
  11. Install the transmission/transaxle.
  12.  
  13. Bleed the clutch hydraulic system and adjust the clutch pedal.
  14.  

ADJUSTMENTS



Pedal Height

See Figure 18



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Fig. Fig. 18: Check pedal height between the floor and top of the pedal pad

  1. Loosen the locknut and adjust the pedal height by means of the pedal stopper or cruise control cancel switch.
  2.  
  3. Pedal height should be 6.61-7.01 in. (14-38mm) on Altima, and 7.56-7.95 in. (52-62mm) on 100SX between the floor and the top of the pedal pad.
  4.  
  5. Tighten the pedal stopper to 12-2 ft. lbs. (2-8 Nm) or the cruise control switch to 9-11 ft. lbs. (12-1 Nm).
  6.  

Free-Play

See Figure 19



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Fig. Fig. 19: Check pedal free-play at the top of the pedal pad

  1. Loosen the locknut and adjust the pedal free-play by means of the master cylinder pushrod.
  2.  
  3. Pedal free-play should be 0.35-0.63 in. (9-2mm) on Altima, and 0.039-0.14 in. (1-3mm) on 100SX between the floor and the top of the pedal pad.
  4.  
  5. Tighten the locknut securely.
  6.  

Clutch Interlock Switch

See Figure 20



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Fig. Fig. 20: Check the clutch interlock switch clearance between the stopper rubber and the clutch interlock switch threads

  1. Loosen the locknut and adjust the clearance between the stopper rubber and the clutch interlock switch threads.
  2.  
  3. Clearance should be 0.004-0.039 in. (0.1-1.0mm) on Altima and 0.012-0.039 in. (0.3-1.0mm) on 100SX.
  4.  
  5. Tighten the locknut securely.
  6.  

 
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