Qashqai J11. Clutch - part 2

 

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Qashqai J11. Clutch - part 2

 

 

CSC (CONCENTRIC SLAVE CYLINDER)

CL-17

< UNIT REMOVAL AND INSTALLATION >

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UNIT REMOVAL AND INSTALLATION

CSC (CONCENTRIC SLAVE CYLINDER)

Exploded View

INFOID:0000000010288568

MR20DD, HRA2DDT and K9K

 R9M

Removal and Installation

INFOID:0000000010288569

CAUTION:

• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).

Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding
parts may damage seal of CSC and may cause clutch fluid leakage.

• Never disassemble CSC.
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately

and wash the affected area with water.

JPDIB0040GB

1.

Transaxle assembly

2.

CSC (Concentric Slave Cylinder)

Refer to 

GI-4, "Components"

 for symbols not described on the above.

JPDIB0048GB

1.

Transaxle assembly

2.

CSC (Concentric Slave Cylinder)

3.

Sealing bolt

Refer to 

GI-4, "Components"

 for symbols not described on the above.

CL-18

< UNIT REMOVAL AND INSTALLATION >

CSC (CONCENTRIC SLAVE CYLINDER)

REMOVAL

1.

Remove transaxle assembly from the vehicle. Refer to 

TM-148, "Removal and Installation"

 (4WD) or 

TM-

88, "Removal and Installation"

 (2WD) .

2.

Remove mounting bolts and then remove CSC from clutch housing.

INSTALLATION

1.

Install CSC to clutch housing and then tighten bolts to the specified torque.

CAUTION:

• Never reuse CSC.
• Never insert and operate CSC because piston and stopper of CSC components may fall off.

2.

Install transaxle assembly. Refer to 

TM-148, "Removal and Installation"

 (4WD) or 

TM-88, "Removal and

Installation"

 (2WD) .

3.

Bleed the air from the clutch hydraulic system. Refer to 

CL-8, "Air Bleeding Procedure"

.

CLUTCH DISC AND CLUTCH COVER

CL-19

< UNIT REMOVAL AND INSTALLATION >

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CLUTCH DISC AND CLUTCH COVER

MR20DD

MR20DD : Exploded View

INFOID:0000000010654843

MR20DD : Removal and Installation

INFOID:0000000010654844

CAUTION:

• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position

every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage
a seal of CSC and may cause clutch fluid leakage. Refer to 

CL-17, "Removal and Installation"

.

• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• Never clean clutch disc using solvent.

REMOVAL

1.

Remove transaxle assembly. Refer to 

TM-35, "Removal and Installation"

.

2.

Remove clutch cover mounting bolts while holding clutch cover.

CAUTION:

Never drop clutch disc.

3.

Remove clutch cover and clutch disc.

CAUTION:

Never drop clutch disc.

4.

Perform inspection after removal. Refer to 

CL-20, "MR20DD : Inspection"

.

INSTALLATION

1.

Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.

Flywheel

Clutch disc

Clutch cover

Input shaft

First step

Final step

: N·m (kg-m, ft-lb)

: Apply lithium-based grease including molybdenum disulphide.

NOTE:
New clutch discs are pre-greased, additional greasing is not required. If refitting used disc, apply a thin coating of grease.

JPDIB0049GB

CL-20

< UNIT REMOVAL AND INSTALLATION >

CLUTCH DISC AND CLUTCH COVER

2.

Apply recommended grease to clutch disc 

 and input shaft 

splines area 

. For recommended grease, refer to 

CL-19,

"MR20DD : Exploded View"

.

CAUTION:

Be sure to apply grease to the points specified. Otherwise,
noise, poor disengagement, or damage to the clutch may
result. Excessive grease may cause slip or judder. And if it
adheres to seal of CSC, it cause clutch fluid leakage. Wipe
out excess grease. Wipe out any grease oozing from the
parts.

3.

Install clutch disc using clutch aligner (A) (commercial service
tool), and temporarily install clutch cover.

CAUTION:

• Never drop clutch disc and clutch cover.

• Be careful with the orientation of the clutch disc.

4.

Tighten clutch cover mounting bolts to the specified torque
evenly in two steps in the numerical order as shown in the fig-
ure.
• For tightening torque, refer to 

CL-19, "MR20DD : Exploded

View"

.

• After installation, perform inspection. Refer to 

CL-20,

"MR20DD : Inspection"

.

5.

Install transaxle assembly. Refer to 

TM-35, "Removal and Instal-

lation"

.

MR20DD : Inspection

INFOID:0000000010654845

INSPECTION AFTER REMOVAL

Clutch Disc

JSDIA3617ZZ

JSDIA3358ZZ

: Engine side

JSDIA6017ZZ

PCIB1772E

CLUTCH DISC AND CLUTCH COVER

CL-21

< UNIT REMOVAL AND INSTALLATION >

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• Measure circumferential runout relative to clutch disc center spline.

If it is outside the specification, replace clutch disc.

• Measure backlash to clutch disc spline and input shaft spline at the

circumference of clutch disc. If it is outside the specification,
replace clutch disc.

• Measure the depth (A) to clutch disc facing rivet heads, using a

calipers. If it exceeds the allowable wear limit, replace clutch disc.

Clutch Cover

• Check clutch cover thrust ring for wear or breakage. If wear or breakage is found, replace clutch cover.

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 sandpaper. If surface is damaged or distorted, replace clutch cover.

INSPECTION AFTER INSTALLATION

Clutch Cover

Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height,
using the diaphragm adjusting wrench (A) (SST: ST20050240).

HRA2DDT

Runout limit/diameter of the area to 
be measured

: Refer to 

CL-31, 

"Clutch Disc"

 .

Maximum allowable spline backlash 
(at outer edge of disc)

: Refer to 

CL-31, 

"Clutch Disc"

.

Facing wear limit (depth to the rivet 
head)

: Refer to 

CL-31, 

"Clutch Disc"

.

SCL221

JPDIB0026ZZ

Tolerance for diaphragm spring 
lever unevenness

: Refer to 

CL-31, 

"Clutch Cover"

.

JPDIB0160ZZ

CL-22

< UNIT REMOVAL AND INSTALLATION >

CLUTCH DISC AND CLUTCH COVER

HRA2DDT : Exploded View

INFOID:0000000010288570

CAUTION:

• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder). Return CSC insert to

original position to remove transaxle assembly. Dust on clutch disc sliding parts may damage seal of CSC and may cause
clutch fluid leakage.

• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.

• When installing, be careful that grease applied to input shaft does not adhere to clutch disc.

• Never clean in solvent on clutch disc.

HRA2DDT : Removal and Installation

INFOID:0000000010288571

CAUTION:

If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts
may damage seal of CSC and may cause clutch fluid leakage.

REMOVAL

1.

Remove transaxle assembly from the vehicle. Refer to  

TM-35, "Removal and Installation"

 (RS6F94R).

2.

Loosen clutch cover mounting bolts.

3.

Remove clutch cover and clutch disc.

CAUTION:

Never drop clutch disc.

INSTALLATION

1.

Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.

2.

Apply recommended grease to clutch disc and input shaft splines.

CAUTION:

Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. And if it adheres to seal of
CSC, it cause clutch fluid leakage. Wipe off excess grease. Wipe off any grease oozing from the
parts.

1.

Flywheel

2.

Clutch disc

3.

Clutch cover

4.

Input shaft

A. First 

step 

B.

Final 

step

 : Apply lithium-based grease including molybdenum disulphide.

NOTE:
New clutch discs are pre-greased, additional greasing is not required. If refitting used disc, apply a thin coating of grease.

Refer to 

GI-4, "Components"

 for symbols not described on the above.

E1DIA0242GB

CLUTCH DISC AND CLUTCH COVER

CL-23

< UNIT REMOVAL AND INSTALLATION >

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3.

Install clutch disc using a suitable clutch aligner (A).

4.

Install clutch cover. Pre-tighten clutch cover mounting bolts.

5.

Tighten clutch cover mounting bolts evenly to the specified
torque in two steps in the order shown in the figure.

6.

Install transaxle assembly to the vehicle. Refer to  

TM-35,

"Removal and Installation"

 (RS6F94R).

HRA2DDT : Inspection

INFOID:0000000010288572

INSPECTION AFTER REMOVAL

CLUTCH DISC

• Measure circumferential runout relative to clutch disc center spline.

If it is outside the specification, replace clutch disc.

• Measure backlash to clutch disc spline and main drive gear spline

at the circumference of clutch disc. If outside the specification,
replace clutch disc.

• Measure the depth “A” to clutch disc facing rivet heads using cali-

pers. If it exceeds the allowable facing wear limit, replace clutch
disc.

CLUTCH COVER

Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using the diaphragm adjusting wrench [SST: ST20050240].

• Check clutch cover thrust ring for wear or breakage. If wear or

breakage is found, replace clutch cover.
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 sandpaper. If surface is damaged or distorted, replace clutch cover.

K9K

E1DIA0243ZZ

Runout limit/diameter of the 
area to be measured

: Refer to 

CL-31, 

"Clutch Disc"

.

Maximum allowable spline 
backlash (at outer edge of disc)

: Refer to 

CL-31, 

"Clutch Disc"

.

Facing wear limit (depth to the 
rivet head)

: Refer to 

CL-31, 

"Clutch Disc"

.

SCL221

JPDIB0026ZZ

Tolerance for diaphragm 
spring lever unevenness

: Refer to 

CL-31, 

"Clutch Cover"

.

PCIB0276E

CL-24

< UNIT REMOVAL AND INSTALLATION >

CLUTCH DISC AND CLUTCH COVER

K9K : Exploded View

INFOID:0000000010288573

CAUTION:

• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder). Return CSC insert to

original position to remove transaxle assembly. Dust on clutch disc sliding parts may damage seal of CSC and may cause
clutch fluid leakage.

• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.

• When installing, be careful that grease applied to input shaft does not adhere to clutch disc.

• Never clean in solvent on clutch disc.

K9K : Removal and Installation

INFOID:0000000010288574

CAUTION:

If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts
may damage seal of CSC and may cause clutch fluid leakage.

REMOVAL

1.

Remove transaxle assembly from the vehicle. Refer to 

TM-35, "Removal and Installation"

.

2.

Loosen clutch cover mounting bolts.

3.

Remove clutch cover and clutch disc.

CAUTION:

Never drop clutch disc.

INSTALLATION

1.

Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.

2.

Apply recommended grease to clutch disc and input shaft splines.

CAUTION:

Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. And if it adheres to seal of
CSC, it cause clutch fluid leakage. Wipe off excess grease. Wipe off any grease oozing from the
parts.

1.

Flywheel

2.

Clutch disc

3.

Clutch cover

4.

Input shaft

 : Apply lithium-based grease including molybdenum disulphide.

NOTE:
New clutch discs are pre-greased, additional greasing is not required. If refitting used disc, apply a thin coating of grease.

Refer to 

GI-4, "Components"

 for symbols not described on the above.

JPDIB0039GB

CLUTCH DISC AND CLUTCH COVER

CL-25

< UNIT REMOVAL AND INSTALLATION >

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3.

Install clutch disc using a suitable clutch aligner (A).

4.

Install clutch cover. Pre-tighten clutch cover mounting bolts.

5.

Tighten clutch cover mounting bolts evenly to the specified
torque in the order shown in the figure.

6.

Install transaxle assembly to the vehicle. Refer to 

TM-35,

"Removal and Installation"

.

K9K : Inspection

INFOID:0000000010288575

INSPECTION AFTER REMOVAL

CLUTCH DISC

• Measure circumferential runout relative to clutch disc center spline.

If it is outside the specification, replace clutch disc.

• Measure backlash to clutch disc spline and main drive gear spline

at the circumference of clutch disc. If outside the specification,
replace clutch disc.

• Measure the depth “A” to clutch disc facing rivet heads using cali-

pers. If it exceeds the allowable facing wear limit, replace clutch
disc.

CLUTCH COVER

Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using the diaphragm adjusting wrench [SST: ST20050240].

• Check clutch cover thrust ring for wear or breakage. If wear or

breakage is found, replace clutch cover.
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 sandpaper. If surface is damaged or distorted, replace clutch cover.

R9M

E1DIA0243ZZ

Runout limit/diameter of the 
area to be measured

: Refer to 

CL-31, 

"Clutch Disc"

.

Maximum allowable spline 
backlash (at outer edge of disc)

: Refer to 

CL-31, 

"Clutch Disc"

.

Facing wear limit (depth to the 
rivet head)

: Refer to 

CL-31, 

"Clutch Disc"

.

SCL221

JPDIB0026ZZ

Tolerance for diaphragm 
spring lever unevenness

: Refer to 

CL-31, 

"Clutch Cover"

.

PCIB0276E

CL-26

< UNIT REMOVAL AND INSTALLATION >

CLUTCH DISC AND CLUTCH COVER

R9M : Exploded View

INFOID:0000000010288579

CAUTION:

• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder). Return CSC insert to

original position to remove transaxle assembly. Dust on clutch disc sliding parts may damage seal of CSC and may cause
clutch fluid leakage.

• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.

• When installing, be careful that grease applied to input shaft does not adhere to clutch disc.

• Never clean in solvent on clutch disc.

R9M : Removal and Installation

INFOID:0000000010288580

CAUTION:

If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts
may damage seal of CSC and may cause clutch fluid leakage.

REMOVAL

1.

Remove transaxle assembly from the vehicle. Refer to 

TM-148, "Removal and Installation"

 or 

TM-88,

"Removal and Installation"

.

E1DIA0229GB

1.

Manual Transmission 

2.

Concentric slave cylinder (CSC)

3.

Bolt

4.

Clutch assembly bolt

5.

Spacer

6.

Clutch cover

7.

Clutch disc

8. 

Flywheel

Refer to 

GI-4, "Components"

 for symbols not described on the above.

NOTE:
New clutch discs are pre-greased, additional greasing is not required. If refitting used disc, apply a thin coating of grease.

CLUTCH DISC AND CLUTCH COVER

CL-27

< UNIT REMOVAL AND INSTALLATION >

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2.

Lock the flywheel using the tool [SST: — (Mot.1431)] (1).

3.

Remove three clutch cover mounting bolts at 120

°

 intervals.

4.

Replace these three bolts by the tool [SST: — (Emb.1761) (1)].

CAUTION:

Never drop clutch disc.

5.

Place the three spacers of tool [SST: — (Emb. 1761)] in contact
using the nuts. 

6.

Gradually remove the six remaining bolts.

7.

NOTE:
These instructions must be respected to prevent twisting the clutch cover:
• Unscrew and gradually remove by quarter turns the three nuts of tool [SST: — (Emb. 1761)] one by one.

8.

Remove clutch cover. 

9.

Remove clutch disc.

INSTALLATION

1.

In case of clutch cover re-used follow the procedure below :
NOTE:
The automatic compensation must be repositioned at its first point.

a.

Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.

b.

Apply recommended grease to clutch disc and input shaft splines.

CAUTION:

Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. And if it adheres to seal of
CSC, it cause clutch fluid leakage. Wipe off excess grease. Wipe off any grease oozing from the
parts.

c.

Place the base of tool (1) [SST: — (Emb.1604)] in a vice jaw.

E1BIA0774ZZ

E1BIA0776ZZ

E1BIA0779ZZ

CL-28

< UNIT REMOVAL AND INSTALLATION >

CLUTCH DISC AND CLUTCH COVER

d.

Install clutch cover onto the base plate then the ball bearing or
bronze ring (1) and the nut (2).

e.

Tighten the nut (1) fully.

f.

Fit a circlip clamp at (1).

g.

Compress the spring (1) to reprime the automatic compensa-
tion.

h.

Slacken off the nut (2) completely (spring compressed).

i.

Release the clutch cover.

j.

Remove the clutch cover from the base plate of tool [SST: —
(Emb.1604)]. 
NOTE:
Be sure that the springs are correctly compressed.

E1BIA0780ZZ

E1BIA0781ZZ

E1BIA0783ZZ

E1BIA0783ZZ

E1BIA0784ZZ

CLUTCH DISC AND CLUTCH COVER

CL-29

< UNIT REMOVAL AND INSTALLATION >

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k.

Install clutch disc on flywheel using a suitable clutch aligner (A).

l.

Install clutch cover (2)  on flywheel (1). Fit the Self Adjusting
tools (A)  using 3 of the cover bolt fixing holes.

m. Use Self Adjusting Clutch tools (A) to depress diaphram fingers

until cover body fixing flange touches flywheel. 

n.

Fit cover bolts in the 6 available holes and tighten to the speci-
fied torque. Refer to 

CL-26, "R9M : Exploded View"

 .

o.

Remove Self Adjusting Clutch tools.
Fit bolts in the 3 remaining holes and tighten to the specified
torque. Refer to 

CL-26, "R9M : Exploded View"

 .

Remove the disc alignement tool (A).

E1DIA0235ZZ

E1DIA0236ZZ

E1DIA0237ZZ

E1DIA0238ZZ

E1DIA0239ZZ

CL-30

< UNIT REMOVAL AND INSTALLATION >

CLUTCH DISC AND CLUTCH COVER

p.

Install transaxle assembly to the vehicle. Refer to 

TM-88, "Removal and Installation"

 (2WD) or 

TM-148,

"Removal and Installation"

 (4WD).

R9M : Inspection

INFOID:0000000010288581

INSPECTION AFTER REMOVAL

CLUTCH DISC

• Measure circumferential runout relative to clutch disc center spline.

If it is outside the specification, replace clutch disc.

• Measure backlash to clutch disc spline and main drive gear spline

at the circumference of clutch disc. If outside the specification,
replace clutch disc.

• Measure the depth “A” to clutch disc facing rivet heads using cali-

pers. If it exceeds the allowable facing wear limit, replace clutch
disc.

CLUTCH COVER

Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using the diaphragm adjusting wrench [SST: ST20050240].

• Check clutch cover thrust ring for wear or breakage. If wear or

breakage is found, replace clutch cover.
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 sandpaper. If surface is damaged or distorted, replace clutch cover.

Runout limit/diameter of the 
area to be measured

: Refer to 

CL-31, 

"Clutch Disc"

.

Maximum allowable spline 
backlash (at outer edge of disc)

: Refer to 

CL-31, 

"Clutch Disc"

.

Facing wear limit (depth to the 
rivet head)

: Refer to 

CL-31, 

"Clutch Disc"

.

SCL221

JPDIB0026ZZ

Tolerance for diaphragm 
spring lever unevenness

: Refer to 

CL-31, 

"Clutch Cover"

.

PCIB0276E

SERVICE DATA AND SPECIFICATIONS (SDS)

CL-31

< SERVICE DATA AND SPECIFICATIONS (SDS) 

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SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

Clutch Control System

INFOID:0000000010288582

Clutch Pedal

INFOID:0000000010288583

Unit: mm (in)

Clutch Disc

INFOID:0000000010288584

Unit: mm (in)

Clutch Cover

INFOID:0000000010288585

Type of clutch control

Hydraulic

Clearance “A” between clutch pedal and ASCD switch threaded 
end while clutch pedal is fully released.

0.2 - 1.96 (0.008 - 0.0772)

Clearance “B” between clutch pedal and Interlock switch threaded 
end while clutch pedal is fully released.

0.2 - 1.96 (0.008 - 0.0772)

Engine type

HRA2DDT

K9K

R9M

MR20DD

Model

225

240

230

Facing size (Outer dia. 

×

 Inner 

dia. 

×

 Thickness)

225 

×

 150 

×

 2.9 (8.9 

×

 

5.91 

×

 0.114)

225 

×

 150 

×

 2.9 (8.9 

×

 

5.91 

×

 0.114)

239 

×

 170 

×

 3.45 (9.41 

×

 6.69 

×

 0.1358)

230 

×

 155 

×

 3.2

(9.06 

×

 6.10 

×

 0.126)

Runout limit/diameter of the 
area to be measured

1.0 (0.039) /215 (8.46) 

dia.

1.0 (0.039) /215 (8.46) 

dia.

1.0 (0.039) /230 (9.06) 

dia.

1.0 (0.039) /240 (9.45) 

dia.

Maximum allowable spline 
backlash (at outer edge of disc)

1.2 (0.047)

1.28 (0.0504)

0.9 (0.035)

Facing wear limit (depth to the 
rivet head)

replace if worn to rivet head

0.3 (0.012)

Engine type

HRA2DDT

K9K

MR20DD

R9M

Transaxle type

RS6F94R

RS6F52A (4WD)

RS6F95R (2WD)

Set-load

5,730 N (584.5 kg, 

1,288.1 lb)

7,100 N (724.2 kg, 

1416.2 lb)

5,700 N (581.4 kg, 

1,281.4 lb)

8,800 N (897.6 kg, 1978.2 lb)

Tolerance for diaphragm 
spring lever unevenness

1.2 mm (0.047 in) or less

not specified

0.8 mm (0.031 in) or less

Diaphragm spring lever 
height (new clutch)

12.6 - 16.2 mm 

(0.496 - 0.64 in)

12.8 - 14.8 mm 

(0.504 - 0.583 in)

20.7 - 22.7 (0.815 - 

0.8937)

26.6 - 29.0 mm (1.047 - 1.142 in)

 

 

 

 

 

 

 

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