clutch NISSAN ALMERA N15 1995 Repair Manual

SERVICEDATAANDSPECIFICATIONS (SOS)
Specifications andAdjustments (Cont'd)
CLUTCH ANDBRAKES

Model
34X68,
34X69,
34X81
34X70, 34X80

I
Reverse clutch
I

Number of

2

drive plates
Number of

2

driven plates
Drive plate
thickness mm(in)
Standard
2.0(0.079)

Wear limit
1.8(0.071)

Clearance mm(in)
Standard
0.5-0.8 (0.020 -0.031)

Allowable
1.2(0.047)

limit
Thicknessmm(in) Partnumber

4.4 (0.173) 31537-31XOO

Thickness 01

4.6(0.181) 31537-31X01

retaining
4.8(0.189) 31537-31X02

plates

5.0(0.197) 31537-31X03
5.2 (0.205) 31537-31X04

I
High clutch
I

Number 01

3 4

drive plates
Number 01

5 6+1

driven plates
Drive plate
thickness mm(in)
Standard
2.0(0.079) 1.6(0.063)

Wear limit
1.8
(0.071) 1.4(0.055)

Clearance mm(in)
Standard
1.4
-1.8 (0.055 -0.071)

-

Allowable
2.4(0.094) 2.6(0.102)

limit
Thicknessmm(in) Part
number

3.8 (0.150) 31537-
3.8(0.150) 31537-
31X11 31X11
4.0 (0.157) 31537-
4.0(0.157) 31537-
31X12 31X12
4.2 (0.165) 31537-
4.2(0.165) 31537-

Thickness 01
31X13
31X13

retaining
4.4(0.173) 31537-
4.4(0.173) 31537-

plates
31X1431X14
46 (0.181) 31537-
4.6(0.181) 31537-
31X15 31X15
4.8 (0.189) 31537-
4.8(0.189) 31537-
31X16 31X16
5.0 (0.197) 31537-
31X17
Model

34X68,
34X69,
34X81
34X70, 34X80

I
Forward clutch
I

Number ofdrive plates

5

Number ofdriven plates
5

Drive platethickness
mm(in)
Standard
1.8
(0.071)

Wear limit
1.6(0.063)

Clearance mm(in)
Standard
0.45-0.85 (0.0177 -0.0335)

Allowable limit
1.85
(0.0728)

Thickness Partnumber
mm (in)

3.6 (0.142) 31537-31X60
3.8 (0.150) 31537-31X61

Thickness ofretaining plate

4.0(0.157) 31537-31X62
4.2 (0.165) 31537-31X63
4.4 (0.173) 31537-31X64
4.6 (0.181) 31537-31X65

IOverrun clutch
I

Number ofdrive plates
3

Number ofdriven plates
4

Drive platethickness
mm(in)
Standard
1.6
(0.063)

Wear limit
1.4
(0.055)

Clearance mm
(in)
Standard
1.0
-1.4 (0.039 -0.055)

Allowable limit
2.0
(0.079)

Thickness Partnumber
mm (in)

3.6 (0.142) 31567-31X72

Thickness 01retaining plate
3.8
(0.150) 31567-31X73
4.0 (0.157) 31567-31X74

.

4.2(0.165) 31567-31X75
4.4 (0.173) 31567-31X76
AT-168

•

Oil
pump sideclear-

0.02-0.04 (0.0008 -0.0016)

ance mm(in)
Innergear
Thickness Partnumber
mm (in)

9.99 -10.00
31346-31XOO
(0.3933 -0.3937)
9.98 -9.99
31346-31X01
(0.3929 -0.3933)
9.97 -998
31346-31X02

Thickness ofinner
(0.3925
-0.3929)

gears andouter gears
Outergear
Thickness Partnumber
mm (in)

9.99 -10.00
31347-31XOO
(0.3933 -0.3937)
9.98 -9.99
31347-31X01
(0.3929 -0.3933)
9.97 -9,98
31347-31X02
(0.3925 -0.3929)

Clearance betweenoil
pump housing and
outer gear
mm(in)
Standard
008-0 15 (0.0031 -0.0059)

Allowable limit
015(0.0059)

Oil pump cover seal
ring clearance
mm(in)
Standard
0.10-0.25 (0.0039 -0.0098)

Allowable limit
0.25(0.0098)
SERVICE
OATAAND SPECIFICATIONS (50S)
Specifications andAdjustments (Cont'd)
OIL PUMP
34X68,

Model
34X69,34X81
34X70, 34X80

ILow
&
reverse brake
I

Number ofdrive plates

5

Number ofdriven plates

5

Drive platethickness
mm(in)
Standard
2.0(0.079)

Wear limit

1.8(0.071)

Clearance mm(in)
Standard
1.4-1.8 (0.055 -0.071)

Allowable limit

2.8(0.110)

.

Thickness Partnumber
mm (in)

36 (0.142)
31667-31X10

Thickness ofretaining
38(0150)
31667-31X11

plate
4.0(0157)
31667-31X12
4.2 (0.165)
31667-31X13
4.4 (0.173)
31667-31X14
4.6 (0.181)
31667-31X15

I
Brake band
I

Anchor endbolttighten-
ing torque
39-5.9 (0.4 -06, 35-52)

N'm (kg-m, in-Ib)
Number ofreturning rev-
olutions foranchor end

2.5:1e0125

bolt
Lock nuttightening

31-36 (3.2 -3.7, 23-27)

torque N'm(kg-m, ft-Ib)

Clutch andbrake return springs
INPUTSHAFT

Unit: mm(in)
Return spring Freelength
Outerdiameter
Forward clutch
Inner
263(1.035) 77(0.303)

(Overrun clutch)

(16
pes) Outer

266
(1.047) 10.6(0.417)

Reverse clutch
(16
pes)
18.6(0.732) 80(0.315)

High clutch
(12
pes)
197(0.776) 11.1(0.437)
Input
shaft sealring
clearance mm(in)
Standard
Allowable limit
0.08
-0.23 (0.0031 -0.0091)
0.23 (0.0091)
PLANETARY CARRIER

Clearance betweenplanetary
carrier andpinion washer
mm(in)
Standard Allowable limit
0.15
-0.70 (0.0059 -0.0276)
080 (0.0315)
AT-169

Sealringclearance

Unit: mm(in)

SERVICE
DATAANDSPECIFICATIONS (SOS)
Specifications andAdjustments (Cont'd)
Table forselecting outputshaftbearing BEARINGRETAINER
adjusting spacer

Dimension "T" Suitablespacer Bearing
retainersealring
clearance mm(in)

REVERSE CLUTCHENDPLAY
Bearing
racesforadjusting totalendplay
Thrust washers foradjusting reverseclutch
end play

Thickness mm(in)
•

31435-31X01
31435-31X02
31435-31X03
31435-31X04
31435-31 X05
31435-31X06
31435-31X07
31435-31X08
31508-31XOO
31508-31X01
31508-31 X02
31508-31X03
31508-31X04
31508-31X05
Part
number
Part number

0.65
-1.00 (0.0256 -0.0394)
0.10
-0.25 (0.0039 -0.0098)
0.25 (0.0098)

mm (in)
0.25-0.55 (0.0098 -0.0217)
0.6 (0024)
0.8 (0.031)
1.0 (0.039)
1.2 (0.047)
1.4 (0.055)
1.6 (0.063)
1.8 (0.071)
2.0 (0.079)
0.65 (0.0256)
0.80 (00315)
0.95 (0.0374)
1.10 (0.0433)
1.25 (0.0492)
1.40 (0.0551)

Thickness
mm(in)
Allowable
limit
Standard
Total endplay
Reverse clutchendplay

mm (in)

TOTAL
ENDPLAY
ACCUMULATOR O-ring
6.26
(0.2465)
6.30 (0.2480)
634 (0.2496)
6.38 (0.2512)
6.42 (0.2528)
6.46 (0.2543)
6.50 (0.2559)
654 (0.2575)
6.58 (0.2591)
6.62 (0.2606)
6.64 (0.2614)
6.66 (0.2622)
6.68 (0.2630)
6.70 (0.2638)
6.72 (0.2646)
6.74 (0.2654)
676 (0.2661)
6.78 (0.2669)
6.80 (0.2677)
6.82 (0.2685)
6.84 (0.2693)
6.86 (0.2701)
6.88 (0.2709)
690 (0.2717)
6.92 (0.2724)
6.94 (0.2732)
696 (0.2740)
6.98 (0.2748)
7.00 (0.2756)
7.02 (0.2764)
7.06 (0.2780)
7.10 (0.2795)
7.14 (0.2811)
7.18 (0.2827)
7.22 (0.2843)
6.29
-6.33 (0.2476 -0.2492)
6.33 -6.37 (0.2492 -0.2508)
6.37 -6.41 (0.2508 -0.2524)
6.41 -6.45 (0.2524 -0.2539)
6.45 -6.49 (0.2539 -0.2555)
6.49 -6.53 (0.2555 -0.2571)
6.53 -657 (0.2571 -0.2587)
6.57 -6.61 (0.2587 -0.2602)
6.61 -6.65 (0.2602 -0.2618)
6.65 -668 (0.2618 -0.2630)
6.68 -670 (0.2630 -0.2638)
6.70 -6.72 (0.2638 -0.2646)
6.72 -674 (0.2646 -0.2654)
6.74 -6.76 (0.2654 -0.2661)
6.76 -6.78 (0.2661 -0.2669)
6.78 -6.80 (0.2669 -0.2677)
6.80 -6.82 (0.2677 -0.2685)
6.82 -684 (0.2685 -0.2693)
6.84 -6.86 (0.2693 -0.2701)
6.86 -6.88 (0.2701 -0.2709)
6.88 -6.90 (0.2709 -0.2717)
6.90 -6.92 (0.2717 -0.2724)
6.92 -6.94 (0.2724 -0.2732)
6.94 -696 (0.2732 -0.2740)
6.96 -698 (0.2740 -0.2748)
6.98 -7.00 (0.2748 -0.2756)
7.00 -702 (0.2756 -02764)
7.02 -7.04 (0.2764 -0.2772)
7.04 -7.06 (0.2772 -0.2780)
7.06 -7.09 (0.2780 -0.2791)
7.09 -7.13 (0.2791 -0.2807)
7.13 -7.17 (0.2807 -0.2823)
7.17 -7.21 (0.2823 -0.2839)
7.21 -7.25 (0.2839 -0.2854)
7.25 -7.29 (0.2854 -0.2870)

Unit:mm(in)
Accumulator Inner
diameter Innerdiameter
(Small) (Large)

SIR
accumulator
26.9
(1.059) 44.2(1.740)

N-D accumulator
34.6
(1.362) 39.4(1.551)
AT-173

TROUBLEDIAGNOSES
Diagnostic Procedure8
CONTROL UNIT
(Malfunction codeNo.71)

Carry outself-diagnosis aftererasing
self-diagnostic results,BR-56.
Does warning lampindicate codeNo.
71 again?

No

Inspect thesystem according tothe
code No. Yes
Replace controlunit.

Brake pedal Diagnostic
Procedure9
SYMPTOM: Pedalvibration andnoise
No

Does thesymptom appearwhenelectri-

SAT797A
calequipment switches(suchashead-
lamp) areoperated?
1.
Apply brake.
2. Start engine.
3. Does thesymptom appearonlywhen
engine isstarted?

No

Yes
Check wheelsensor shieldgrou.nd
secured withcontrol unitmounting bolt.
Refer toBR-41. Yes
Carryoutself-diagnosis.
Refer toBR-53 (Europe)
or BR-56 (Except
Europe).
Go to
Ii1
inDiagnostic
Procedure 11,BR-83.

OK

Check control unitpinterminals for
damage orthe connection ofcontrol
unit harness connector.
Reconnect controlunitharness connec-
tor. Then retest.

Note: ABSmayoperate andcause vibration underanyofthe
following conditions.
• Applying brakegradually whenshifting oroperating clutch.
• Low friction (slippery) road.
• High speed cornering.
• Driving overbumps andpotholes.
• Engine speedisover 5,000 rpmwith vehicle stopped.
BR-82

CLUTCH
SECTION
CL
CONTENTS
PRECAUTIONS ANDPREPARATION 2
Precautions 2
Preparation 2
CLUTCH SYSTEM-Hydraulic Type
3

CLUTCH SYSTEM-Mechanical Type 4
INSPECTION ANDADJUSTMENT
5

Adjusting ClutchPedal 5
Bleeding Procedure -Hydraulic type 5
HYDRAULIC CLUTCHCONTROL.. 6
Clutch Master Cylinder 6Operating
Cylinder 7
Clutch Damper 8
CLUTCH RELEASE MECHANiSM 9
CLUTCH DISCANDCLUTCH COVER 11
Clutch Disc 11
Clutch CoverandFlywheel 12
SERVICE DATAANDSPECIFICATIONS (SDS)13
General Specifications 13
Inspection andAdjustment 14
•

PRECAUTIONSANDPREPARATION

Precautions

• Recommended fluidisbrake fluid"DOT 3".
• Donot reuse drained brakefluid.
• Becareful nottosplash brakefluidonpainted areas.
• When removing andinstalling clutchpiping, useTool.
• Use new brake fluidtoclean orwash allparts ofmaster
cylinder, operating cylinderandclutch damper.
• Never usemineral oilssuch asgasoline orkerosene. Itwill
ruin therubber partsofthe hydraulic system.

Tool number
Tool name
SBR820B

WARNING:
After cleaning clutchdisc,wipe itwith adust collector. Donot
use compressed air.

Preparation

SPECIAL SERVICE TOOLS

Description

New

GG94310000
Flare nuttorque wrench
KV30101600 (New)
KV30101000 (Former)
Clutch aligning bar
ST20050240 Diaphragm spring
adjusting wrench
NT406
NT645
NT404
Removing
andinstalling clutchpiping

a:
10
mm
(0.39
in)

Installing clutchcoverandclutch disc:
a:
15.9
mm
(0.626 In)dia.
b: 17.9 mm(0.705 in)dia.
c: 40 mm (1.57 in)

Adjusting unevenness ofdiaphragm spring
of clutch cover

a: 150 mm (5.91 in)
b: 25
mm
(0.98
in)

Tool name
Description
COMMERCIAL
SERVICETOOLS

Equivalent to
GG9431 0000

CD
Flare nutcrows foot

@
Torque wrench

NT360
Removing
andinstalling clutchpiping

a: 10 mm (0.39 in)

CL-2

SCL667
CLUTCH
SYSTEM -Hydraulic Type

m
(bl:
Apply lithium-based greaseincluding
molybdenum disulphide.
~ :N.m (kg-m. ft-Ib)
~ :N.m (kg-m. in-Ib)
•

G)
Clutch pedalbracket

@
Clutch master cylinder

@
Assist spring

@
Bushing

@
Pin

@
Stopper rubber

(J)
Operating cylinder

@
Airbleeder screw
@

Withdrawal lever

@J
Release bearing

@
Clutch hose

@
Operating cylindersupport
bracket

@
Clutch lever

@
Spring pin
@ Operating cylinderbracket

CL-3 @

Clutch cover

@
Clutch disc

@
Clutch pedal

@
Clevis pin

@
Pedal stopper

@
Fulcrum pin

CLUTCHSYSTEM-Mechanical Type

SEC. 300'307.465

SCL668
\~
8-11
<D
(RHO model)

(0.8 -1.1, 69-95)

r&#34;&#34;
@
@m

~~~ ~
/~

to.J 16-22
f
77&#39;\
-j, ~&#39;

, (1.6.2.2,12-16)~ ~
M-

. <D
(LHD model)
Of~ &#39;:,

,/ I
r&#39;;, ~~
I&#39;
@
to.J 16•22 (1.6 -2.2, 12•16)

/ fA&#39;l
@m~
a!&#39;,~~
I

,/&#39; ~~ {l
,-0 ~
be\.\~&#39;:~ @

<
01Q&#39;?0&#39;J:l&#39;e..------ ,
d~~

~;, 1
v,~

~, ~i,:
1r
J
~m
to.J13-16

c
I~..--.......

~JO
a,
&#39;,@/ :&#39;~&#39; ~ (1.3•1.6, 9-12)

@
to.J 16-22 ~
be c
_1
L~---- .~
.Jl

(1.6 -2.2, 12-16)
&#39;~d&#39; ~
C1J.~,
@m

&#39;m (

@ ,

@
to.J 13-16 (1.3 •1.6, 9•12) .~. ~
I

to.J 16-22 (1.6 -2.2, 12-16)
@~ ~
@ ~~@

m(Q .

-m~.

m(Q ~

~h
<:

(7\I~ ~ .~

\ ~J;i::::;~

l&#34;J&#34; -
29 (2.2 -3.0,
1.-
22)1>
0~~
<bl~&#39;&#34;
&#39;I

~ ¥:11)

@-..........t>&#39;&#34;l(0.8-1.1,69-95)
/l~~

~ ~I!C!
<bl
I!C!
<bl&#39;
ApplV Ilth&#39;&#34;m-&#34;,,&#39; om,,,
&#39;001&#34;&#34;00

m
(Q
molybdenumdisulphide.

Iiii\ .
[OJ;
N.m (kg-m, ft-lb)

~
IjJ;N&#39;m (kg-m, in-Ib)

G)
Clutch pedalbracket
(1)
Return
spring @
Clutch pedal

@
Insulator
@

Clutch lever
@

Bushing

@
Assist spring
@

Spring pin
@

Pedal stopper

@
Withdrawal lever
@J
Release
bearing
@

Lock nut

@
Clutch cover
@

Stopper rubber
@

Fulcrum pin

@
Clutch disc

CL-4

INSPECTIONANDADJUSTMENT

Pedal stopper
Dash lower
panel (except
CD20 engine //
model)

/L
Floor car-pet

L
Dash reinforcement panel
(CD20 engine model)
Adjusting
ClutchPedal

1. Adjust pedalheight withpedal stopper.

Pedal height
&#34;H&#34;:

Refer to
50S,
CL-14.

•

SCL625
SCL423 -
For mechanical type-

2. Adjust withdrawal leverplay&#34;8&#34;according tothe following
procedure_
a. Push withdrawal leverbyhand untilresistance isfelt, and
then tighten adjusting nut.
b. Turn backadjusting nut2.5to3.5 turns, andthen tighten lock
nut.

Withdrawal leverplay
&#34;B&#34;:

2.5 -3.5 mm (0.098 -0.138 in)
lock nut:

~: 3-
4 N&#39;m (0.3-0.4 kg-m, 26-35 in-Ib)
- For hydraulic typeandmechanical type-

3. Asafinal check, measure pedalfreetravel &#34;A&#34;atcenter of
pedal pad.

Pedal freetravel
&#34;A&#34;:

Refer to
50S,
CL-14.
B
Bleeding Procedure -Hydraulic type
Bleed airaccording tothe following procedure.
• Carefully monitorfluidlevel atmaster cylinder during
bleeding operation.

1. Top upreservoir withrecommended brakefluid.
2. Connect atransparent vinyltubetoair bleeder valve.
3. Fully depress clutchpedalseveral times.
4. With clutch pedaldepressed, openbleeder valvetorelease
air, then close bleeder valve.
5. Repeat steps3through 5above untilclear brake fluid

SCL613
comesoutofair bleeder valve.

SCL341-A

Adjusting
nut
Lock
nut

CL-5

HYDRAULICCLUTCHCONTROL
Clutch Master Cylinder

SEC. 305

SCL669

~
2.9 •5.9 (0.30 •0.60, 26.0•52.2)

@
@
m
CD
Rubbing surfaceto
piston assembly
@LHD
models
m @:Apply silicone grease,
m
CD:
Apply rubber lubricant.

Iil :
N.m (kg-m. in-Ib)
CD

/

(1), ~
1&#39;.

~&#39;. ~&#34;. @liJa-
11

( ~I&#39;
(08.&#39;.1,

,<
I
~f
/@O@I1I!@(A&#39;:o&#39;::&#34;&#39;1

~ @
m@(LHDmodels)
Rubbing surfaceto

@.
Apply brakefluidwhen assembling.
(jJ)
m @(RHD models) pushrod
~ m@(LHD models)

*
Take careofthe bolt direction Contactsurfacetopiston assembly
m@ :Apply rubber grease.

@~
1.5-2.9 (0.15 -0.30, 13.0-26.0)

• Remove thisstopper, when
removing pistonandreturn spring.

(j)
~
2.5 -3.9 (0.25 -0.40, 21.7-34.7)

(1)
Piston assembly

@
Reservoir
cap

@
Piston cup

(])
Reservoir
band

@
Return spring
@
Cylinder body

@
Reservoir
tank

@
Packing

@
Reservoir hose
@)

Valve stopper
@

Push rod

@
Stopper

@
Stopper ring

@
Dustcover

@
Lock nut

DISASSEMBLY ANDASSEMBLY

• Push piston intocylinder bodywithscrewdriver when
removing andinstalling valvestopper.
• Align groove ofpiston assembly andvalve stopper when
installing valvestopper.
• Check direction ofpiston cups.

c;D.=:
=.J3@

Groove
SCL214 CL-6