Nissan Frontier D40. Manual - part 184

CL-22

< REMOVAL AND INSTALLATION >

CLUTCH DISC, CLUTCH COVER

• Broken thrust ring will make a clinking sound when cover is shaken up and down.

• If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,

repair the surface with emery paper. If surface is damaged or distorted, replace the assembly.

Flywheel

• Check contact surface of flywheel for slight burns or discoloration.

If any are found, repair flywheel with emery paper.

• Check the flywheel runout. Refer to 

EM-88, "Inspection After Dis-

assembly"

.

5M/T : Adjustment after Installation

INFOID:0000000005589316

ADJUSTMENT AFTER INSTALLATION

Clutch Cover

With the clutch cover installed on the vehicle, check the diaphragm
spring toe height for unevenness. If unevenness exceeds the limit,
adjust the diaphragm spring toe height using Tool.

6M/T

6M/T : Exploded View

INFOID:0000000005276153

PBIC2168E

Uneven limit of diaphragm 
spring toe height

: Refer to 

CL-25, "Clutch 

Cover"

.

Tool number

: ST20050240 (

—

)

PCIB0276E

1.

Flywheel

2.

Clutch disc

3.

Clutch cover

WCIA0522E

CLUTCH DISC, CLUTCH COVER

CL-23

< REMOVAL AND INSTALLATION >

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6M/T : Removal and Installation

INFOID:0000000005276154

CAUTION:

• Do not clean the clutch disc with solvent.
• When installing, do not get grease from the main drive shaft onto the clutch disc friction surface. 
• If the flywheel is removed, align the dowel pin with the smallest hole of flywheel. Refer to 

EM-215,

"Disassembly and Assembly"

.

REMOVAL

1.

Remove the manual transmission from the vehicle. Refer to 

TM-69, "Removal and Installation from Vehi-

cle (For 2WD Models)"

 or 

TM-71, "Removal and Installation from Vehicle (For 4WD Models)"

.

2.

Remove the clutch cover bolts using power tool. Remove the clutch cover and clutch disc.

INSTALLATION

1.

Apply recommended grease to clutch disc and main drive shaft spline.

CAUTION:

Do not allow grease to contaminate the clutch facing.

2.

Install clutch disc and clutch cover. Pre-tighten the bolts and
install Tool. Then tighten the clutch cover bolts evenly in two
steps to the specified torque in the order shown. Refer to 

CL-22,

"6M/T : Exploded View"

.

3.

Install the manual transmission. Refer to 

TM-69, "Removal and Installation from Vehicle (For 2WD Mod-

els)"

 or 

TM-71, "Removal and Installation from Vehicle (For 4WD Models)"

.

6M/T : Inspection after Removal

INFOID:0000000005276155

INSPECTION AFTER REMOVAL

Clutch Disc

• Check the wear of the clutch disc facing.

Tool number

: ST20630000 (J-26366)

LCIA0391E

Clutch disc facing 
wear

: Refer to 

CL-25, "Clutch Disc"

.

SCL229

CL-24

< REMOVAL AND INSTALLATION >

CLUTCH DISC, CLUTCH COVER

• Check the runout and backlash of the clutch disc. If the measure-

ment exceeds the specification, replace the clutch disc.

Clutch Cover

• Check clutch cover thrust ring for wear or damage. If wear or damage is found, replace clutch cover assem-

bly.
NOTE:
• Worn thrust ring will generate a beating noise when tapped at the rivet with a hammer.
• Broken thrust ring will make a clinking sound when cover is shaken up and down.

• If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,

repair the surface with emery paper. If surface is damaged or distorted, replace the assembly.

Flywheel

• Check contact surface of flywheel for slight burns or discoloration.

If any are found, repair flywheel with emery paper.

• Check the flywheel runout. Refer to 

EM-225, "Inspection After Dis-

assembly"

.

6M/T : Adjustment after Installation

INFOID:0000000005589317

ADJUSTMENT AFTER INSTALLATION

With the clutch cover installed on the vehicle, check the diaphragm
spring toe height for unevenness. If unevenness exceeds the limit,
adjust the diaphragm spring toe height using Tool.

Runout and backlash

: Refer to 

CL-25, "Clutch Disc"

.

SCL221

PBIC2168E

Uneven limit of diaphragm 
spring toe height

: Refer to 

CL-25, "Clutch 

Cover"

.

Tool number

: ST20050240 (

—

)

PCIB0276E

SERVICE DATA AND SPECIFICATIONS (SDS)

CL-25

< SERVICE DATA AND SPECIFICATIONS (SDS) 

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SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

Clutch Control System

INFOID:0000000005276156

Clutch Master Cylinder

INFOID:0000000005276157

Unit: mm (in)

Clutch Operating Cylinder

INFOID:0000000005276158

Unit: mm (in)

Clutch Disc

INFOID:0000000005276159

Unit: mm (in)

Clutch Cover

INFOID:0000000005276160

Unit: mm (in)

Clutch Pedal

INFOID:0000000005276161

Unit: mm (in)

Type of clutch control

Hydraulic

Inner diameter

15.87 (5/8)

Inner diameter

19.05 (3/4)

Engine model

QR25DE

VQ40DE

Model

240

260

Transmission Model

5 M/T

6 M/T

Facing size (Outer dia. 

×

 inner dia. 

×

 thickness)

240 

×

 160 

×

 3.5 (9.45 

×

 6.30 

×

 0.138)

260 

×

 190 

×

 3.2 (10.24 

×

 7.48 

×

 0.126)

Wear limit (depth to rivet head)

0.3 (0.012)

Runout limit/diameter of the area to be measured

0.7 (0.028) or less/230 (9.06) dia.

1.0 (0.039) or less/250 (9.84) dia.

Maximum backlash of spline (at outer disc edge)

1.0 (0.039)

Engine model

QR25DE

VQ40DE

Transmission Model

5 M/T

6 M/T

Set-load

5890 N (600 kg, 1324 lb)

8340 N (850 kg, 1875 lb)

Diaphragm spring lever height

37.0 - 39.0 (1.457 - 1.535)

44.0 - 46.0 (1.732 - 1.811)

Uneven limit of diaphragm spring toe height

0.7 (0.028)

Clearance 

″

C

″

 between pedal stopper rubber and clutch interlock switch 

threaded while clutch pedal is fully depressed.

0.1 - 1.0 (0.004 - 0.039)