Nissan Frontier D22. Manual - part 203

CLUTCH RELEASE MECHANISM

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Inspection

ECS007GY

Check the following items, and replace if necessary.

●

Release bearing, to see that it rolls freely and is free from noise, cracks, pitting or wear

●

Release sleeve and withdrawal lever rubbing surface, for wear, rust or damage

Lubrication

ECS007GZ

●

Apply recommended grease to contact surface and rubbing surface.

CAUTION:

Too much lubricant might damage clutch disc facing.

WCL043

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CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

PFP:30100

Components

ECS007H0

Inspection and Adjustment

ECS007H1

CLUTCH DISC

Check the following items, and replace if necessary.

●

Clutch disc, for burns, discoloration, oil or grease leakage

●

Clutch disc, for wear of facing

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Clutch disc, for backlash of spline and runout of facing

WCL034

Wear limit of facing 
surface to rivet head

: 0.3 mm (0.012 in)

ACL063

Maximum backlash of spline 
(at outer edge of disc) 

: 1.0 mm (0.039 in)

Runout limit of facing (at 
outer edge of disc) 

: 1.0 mm (0.039 in)

Distance of runout check 
point (from hub center) 

Model 240

: 115 mm (4.53 in)

Model 250

: 120 mm (4.72 in)

ACL064

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

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CLUTCH COVER AND FLYWHEEL

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Check clutch cover, installed on vehicle, for uneven diaphragm
spring toe height.

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If out of limit, adjust the height with Tool.

FLYWHEEL INSPECTION

CAUTION:

Do not allow any magnetic materials to contact the ring gear teeth.

●

Inspect contact surface of flywheel for slight burns or discoloration. Clean flywheel with emery paper.

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Check flywheel runout. Refer to 

EM-58, "FLYWHEEL/DRIVE

PLATE RUNOUT"

  (KA24DE), or 

EM-140, "FLYWHEEL/DRIVE

PLATE RUNOUT"

  (VG33E, VG33ER), “Flywheel/Drive Plate

Runout”.

Installation

ECS007H2

CAUTION:

Too much lubricant may damage clutch disc facing.

●

Apply recommended grease to contact surface of splines.

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Insert Tool into clutch disc hub when installing clutch cover and disc.

●

Be careful not to allow grease to contaminate clutch facing.

Uneven limit of diaphragm spring toe height

KA24DE, VG33ER

: 0.7 mm (0.028 in)

VG33E

: 0.5 mm (0.020 in)

Tool number

: ST20050240 ( — )

SCL466

AEM100

Tool number

: ST20630000 (J26366)

WCIA0172E

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CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

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Tighten bolts in numerical order, in two steps with Tool in place.

KA24DE, VG33E models

Step 1

: 10 - 20 N·m (1.0 - 2.0 kg-m, 8 - 14 ft-lb)

Step 2

: 22 - 29 N·m (2.2 - 3.0 kg-m, 16 - 22 ft-lb)

Tool number

: ST20630000 (J26366)

WCIA0173E

VG33ER model

Step 1

: 10 - 20 N·m (1.0 - 2.0 kg-m, 8 - 14 ft-lb)

Step 2

: 34.3 - 44.1 N·m (3.5 - 4.5 kg-m, 26 - 32 ft-lb)

Tool number

: ST20630000 (J26366)

WCIA0174E