Nissan Pick-ups and Pathfinder 1989-1995

Driven Disc and Pressure Plate

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The clutch is a hydraulically operated single plate, dry friction disc, diaphragm spring type.

It is operated by a clutch pedal which is mechanically connected to a clutch master cylinder. When the pedal is depressed, the piston in the master cylinder is moved in the master cylinder bore. This movement compresses the hydraulic fluid in the cylinder causing pressure which is transferred through a tube to the slave cylinder.

The slave cylinder is mounted to the clutch housing with its piston connected to the clutch release lever. The hydraulic pressure in the slave cylinder forces the cylinder piston to travel down the cylinder bore and move the clutch release lever, disengaging the clutch.

REMOVAL & INSTALLATION



See Figures 1 through 14


CAUTION
The clutch driven disc contains asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake cleaning fluid.

  1. Raise the vehicle and support it with jackstands.
  2.  
  3. Remove the transmission.
  4.  
  5. Mark the clutch assembly-to-flywheel relationship with paint or a center punch so that the clutch assembly can be reassembled in the same position from which it is removed. Insert a clutch aligning tool (dummy shaft) into the hub. This tool is available from your local Nissan dealer or an auto parts store. It is important to support the weight of the clutch while the retaining bolts are being removed.
  6.  
  7. Loosen the clutch cover-to-flywheel attaching bolts, one turn at a time in an alternating sequence, until the spring tension is relieved to avoid distorting or bending the clutch cover. Remove the clutch assembly.
  8.  

To install:
  1. Inspect the flywheel for scoring, roughness, or signs of overheating. Light scoring may be cleaned up with emery cloth, but any deep grooves or scoring warrant replacement or refacing (if possible) of the flywheel. If the clutch facings or flywheel are oily, inspect the transmission front cover oil seal, the pilot bushing, and engine rear seals, etc. for leakage, and correct before replacing the clutch. If the pilot bushing in the crankshaft is worn, replace it. Install it using a soft hammer. The factory supplied part does not have to be oiled, but check the part manufacturer's instructions if you are using an aftermarket part. Inspect the clutch cover for wear or scoring, and replace as necessary. The pressure plate and spring cannot be disassembled; you must replace the clutch cover as an assembly.
  2.  
  3. Inspect the clutch release bearing. If it is rough or noisy, it should be replaced. The bearing can be removed from the sleeve with a puller; this requires a press to install the new bearing. After installation, coat the groove in the sleeve, the contact surfaces of the release lever, pivot pin and sleeve, and the release bearing contact surfaces on the transmission front cover with a light coat of grease. Be careful not to use too much grease, which will run at high temperatures and get onto the clutch facings. Reinstall the release bearing on the lever.
  4.  



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Fig. Fig. 1: Clutch installation tool



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Fig. Fig. 2: Tighten the clutch housing bolts in this order



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Fig. Fig. 3: Exploded view of the clutch assembly



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Fig. Fig. 4: Exploded view of the clutch release mechanism



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Fig. Fig. 5: View of the clutch assembly after the transmission is removed



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Fig. Fig. 6: Install a special aligning tool before removing the clutch assembly



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Fig. Fig. 7: When removing the clutch assembly lock the flywheel from turning



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Fig. Fig. 8: View of the clutch pressure plate and disc assembly after the retaining bolts are removed



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Fig. Fig. 9: When removing the flywheel assembly lock the flywheel from turning to aid in removal



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Fig. Fig. 10: Remove the flywheel, do not forget to check the pilot bushing



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Fig. Fig. 11: Install the flywheel, make sure to tighten the retaining bolts in a crisscross pattern



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Fig. Fig. 12: Install the clutch assembly, make sure to tighten the retaining bolts in a crisscross pattern and lock the flywheel from turning



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Fig. Fig. 13: View of the transmission removed-note the clutch release bearing in position



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Fig. Fig. 14: Remove the release bearing from the transmission mainshaft

  1. Apply a thin coat of grease to the pressure plate wire ring, diaphragm spring, clutch cover grooves and the drive bosses on the pressure plate.
  2.  
  3. Apply a thin coat of Lubriplate to the splines in the driven plate. Slide the clutch disc onto the splines, and move it back and forth several times. Remove the disc and wipe off the excess lubricant. Be very careful not to get any grease on the clutch facings.
  4.  
  5. Assemble the clutch cover and the clutch plate on the clutch alignment arbor.
  6.  
  7. Align the marks made on the clutch cover and the flywheel (if the old cover is being used) and install the clutch cover-to-flywheel attaching bolts. Three dowels are used to locate the clutch cover on the flywheel properly. Tighten the bolts in an alternating sequence one turn at a time to 16-22 ft. lbs. (22-29 Nm). Remove the aligning arbor (dummy shaft).
  8.  
  9. Install the transmission.
  10.  

 
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