Replace clutch NISSAN 350Z 2007 Z33 Clutch Workshop Manual

CL-2
PRECAUTIONS
Revision: 2006 November2007 350Z
PRECAUTIONSPFP:00001
Precautions for Battery ServiceNCS00001
Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interfer-
ence between the window edge and the vehicle when the door is opened/closed. During normal operation, the
window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic
window function will not work with the battery disconnected.
Service Notice or PrecautionsNCS00002

Recommended clutch fluid is brake fluid “DOT 3”. Refer to MA-11, "RECOMMENDED FLUIDS AND
LUBRICANTS" .

Never reuse drained clutch fluid.

Be careful not to splash clutch fluid on painted areas.

When removing clutch tube, use a flare nut wrench.

When installing clutch tube, use a flare nut torque wrench.

Use new clutch fluid to clean or wash all parts of master cylinder.

Never use mineral oils such as gasoline or kerosene. It will ruin
the rubber parts of the hydraulic system.

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

Do not disassemble CSC body.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not use compressed air.SBR686C

CL-4
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Revision: 2006 November2007 350Z
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartNCS00005
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
Reference pageCL-5CL-7CL-9CL-11EM-101CL-16EM-134
SUSPECTED PARTS (Possible cause)
CLUTCH PEDAL (Free play out of adjustment)
CLUTCH LINE (Air in line)
MASTER CYLINDER PISTON CUP (Damaged)
CSC (Concentric Slave Cylinder) (Worn, dirty or damaged)
ENGINE MOUNTING (Loose)
CLUTCH DISC (Out of true)
CLUTCH DISC (Runout is excessive)
CLUTCH DISC (Lining broken)
CLUTCH DISC (Dirty or burned)
CLUTCH DISC (Oily)
CLUTCH DISC (Worn out)
CLUTCH DISC (Hardened)
CLUTCH DISC (Lack of spline grease)
DIAPHRAGM SPRING (Damaged)
DIAPHRAGM SPRING (Out of tip alignment)
PRESSURE PLATE (Distortion)
FLYWHEEL (Distortion)
SymptomClutch grabs/chatters 1 2 2 2 2 2
Clutch pedal spongy 1 2 2
Clutch noisy 1
Clutch slips 1 2 2 3 4 5
Clutch does not disengage 1 2 3 4 5 5 5 5 5 5 6 6 7

CLUTCH PEDAL
CL-5
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Revision: 2006 November2007 350Z
CLUTCH PEDALPFP:46540
On-Vehicle Inspection and AdjustmentNCS00006
1. Check to see if the clevis pin floats freely in the bore of the
clutch pedal. It should not be bound by the clevis or clutch pedal.
a. If the clevis pin is not free, check that the pedal stopper bolt or
ASCD clutch switch is not applying pressure to the clutch pedal
causing the clevis pin to bind. To adjust, loosen lock nut and turn
pedal stopper bolt or ASCD clutch switch.
b. Tighten the lock nut. Refer to CL-6, "
Removal and Installation" .
c. Verify that the clevis pin floats in the bore of the clutch pedal. It
should not be bound by the clutch pedal.
d. If the clevis pin is still not free, remove the clevis pin and check
for deformation or damage. Replace clevis pin if necessary.
Leave pin removed for step 2.
2. Check clutch pedal stroke for free range of movement.
a. With the clevis pin removed, manually move the clutch pedal up and down to determine if it moves freely.
b. If any sticking is noted, replace the related parts (clutch pedal assembly, bushing etc.). Re-assemble the
clutch pedal and re-verify that the clevis pin floats freely in the bore of the clutch pedal.
3. Adjust clearance “C” while depressing clutch pedal fully. (With
clutch interlock switch)
4. Check clutch hydraulic and system components (clutch master
cylinder, CSC, etc.) for sticking or binding.
a. If any sticking or binding noted, repair or replace related parts as
necessary.
b. If hydraulic system repair was necessary, bleed the clutch
hydraulic system. Refer to CL-7, "
Bleeding" .
NOTE:
Do not use a vacuum assist or any other type of power bleeder
on this system. Use of a vacuum assist or power bleeder will not
purge all the air from the system.Clearance C : 0.1 - 1.0 mm (0.004 - 0.039 in)
PCIB0907E
PCIB0757E

CL-6
CLUTCH PEDAL
Revision: 2006 November2007 350Z
Removal and InstallationNCS00007
COMPONENTS
REMOVAL
1. Remove kicking plate. Refer to EI-35, "Removal and Installation (for Coupe Models)" or EI-37, "Removal
and Installation (for Roadster Models)" .
2. Remove footrest. Refer to EI-43, "
Removal and Installation" .
3. Remove dash side finisher (LH). Refer to IP-11, "
Removal and Installation" .
4. Remove instrument driver panel lower. Refer to IP-11, "
Removal and Installation" .
5. Remove the clutch interlock switch and ASCD clutch switch (with ASCD) connectors and harness.
6. Remove the snap pin and clevis pin.
7. Remove the pedal bracket mounting bolt and nuts and then remove the clutch pedal assembly.
INSPECTION AFTER REMOVAL
Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found, replace
the clutch pedal assembly.
INSTALLATION
Note the following, and install in the reverse order of removal.

Tighten pedal stopper bolt lock nut or ASCD clutch switch lock nut to the specified torque after installing
the clutch pedal assembly in the vehicle and adjusting the pedal free play. Refer to CL-5, "
On-Vehicle
Inspection and Adjustment" .

After installing the clutch interlock switch, adjust the switch position. Refer to CL-5, "On-Vehicle Inspection
and Adjustment" .
1. Clutch interlock switch 2. Bracket 3. Clevis pin
4. Pedal stopper rubber 5. Clutch pedal 6. Stopper rubber
7. Pedal pad 8. ASCD clutch switch (With ASCD) 9. Pedal stopper bolt (Without ASCD)
10. Bushing 11. Snap pin
Refer to GI-11, "
Components" , and the followings for the symbols in the figure.
: Apply lithium-based grease including molybdenum disulphide.
PCIB1678E

CLUTCH MASTER CYLINDER
CL-9
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Revision: 2006 November2007 350Z
8. Remove reservoir tank mounting nut and then remove reservoir
tank.
9. Remove clutch tube using a flare nut wrench.
10. Remove mounting nuts and then remove packing and master
cylinder assembly.
INSTALLATION
1. Check position of clevis and push rod. If measurement is outside
the standard length, adjust position of clevis and push rod.
2. Install packing and master cylinder assembly and tighten mount-
ing nuts to the specified torque. Refer to CL-8, "
Components" .
3. Connect clutch tube to master cylinder assembly and tempo-
rarily tighten flare nut.
4. Tighten clutch tube flare nut to the specified torque using a flare
nut torque wrench. Refer to CL-15, "
Removal and Installation" .
5. Install clevis to the clutch pedal, and fix clevis with clevis pin.
6. Install snap pin to the clevis pin.
7. Install reservoir hose to the nipple. Install the reservoir tank to
the vehicle, and then tighten mounting nuts to the specified
torque.
8. After completing this procedure, inspect and adjust for clutch
pedal and then bleed the clutch hydraulic system. Refer to CL-5,
"On-Vehicle Inspection and Adjustment" and CL-7, "Bleeding" .
9. Install hoodledge cover.
10. Install instrument driver panel lower. Refer to IP-11, "
Removal
and Installation" .
11. Install dash side finisher. Refer to IP-11, "
Removal and Installation" .
12. Install footrest. Refer to EI-43, "
FLOOR TRIM" .
13. Install kicking plate. Refer to EI-35, "
Removal and Installation (for Coupe Models)" or EI-37, "Removal
and Installation (for Roadster Models)" .
Disassembly and AssemblyNCS0000A
DISASSEMBLY
1. Remove spring pin, nipple and reservoir seal from cylinder body
using a pin punch.
2. Loosen push rod lock nut. Remove clevis and lock nut.
3. Remove the seat from the cylinder body.
4. Remove the stopper ring and stopper, and then remove the
push rod, piston assembly and return spring from the cylinder
body.
CAUTION:
Restrain the push rod while doing this because there is a
danger the piston assembly will fly out of the cylinder body.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.
SCIA1587E
Length “L” : 111.0 ± 0.5 mm (4.37 ± 0.02 in)
: 5.8 N·m (0.59 Kg-m, 51 in-lb)
SCIA5158E
SCIA1587E
PCIB0274E

CSC (CONCENTRIC SLAVE CYLINDER)
CL-11
D
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F
G
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Revision: 2006 November2007 350Z
CSC (CONCENTRIC SLAVE CYLINDER)PFP:30500
Removal and InstallationNCS0029M
CAUTION:

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

Do not disassemble CSC body.

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.
COMPONENTS
REMOVAL
1. Remove transmission assembly from the vehicle. Refer to MT-18, "Removal and Installation" .
1. Transmission assembly 2. CSC (Concentric Slave Cylinder)
body3. Dust cover
4. CSC (Concentric Slave Cylinder)
tube5. Air bleeder valve
Refer to GI-11, "
Components" for the symbols in the figure.
PCIB1940E

CL-16
CLUTCH DISC, CLUTCH COVER
Revision: 2006 November2007 350Z
CLUTCH DISC, CLUTCH COVERPFP:30100
Removal and InstallationNCS0000G
COMPONENTS
CAUTION:

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

Be careful not to bring any grease into contact with the clutch disc facing, pressure plate surface
and flywheel surface.

If flywheel is removed, align dowel pin with the smallest hole of flywheel. Refer to EM-111,
"ASSEMBLY" .

When installing, be careful that grease applied to main drive gear does not adhere to clutch disc.

Do not clean in solvent on clutch disk.
REMOVAL
1. Remove transmission assembly from the vehicle. Refer to MT-18, "Removal and Installation" .
2. Loosen clutch cover mounting bolts with power tool. Remove clutch cover and clutch disc.
CAUTION:
Do not drop clutch disc.
1. Flywheel 2. Clutch disc 3. Clutch cover
4. Main drive gear
A. First step
B. Final step
Refer to GI-11, "
Components" , and the followings for the symbols in the figure.
: Replace the parts as a set.
: Apply lithium-based grease including molybdenum disulphide
PCIB1939E

CLUTCH DISC, CLUTCH COVER
CL-17
D
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MA
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Revision: 2006 November2007 350Z
INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc

Measure circumference runout relative to the clutch disc center
spline. If it is outside the specification, replace clutch disc and
clutch cover as a set.

Measure backlash for clutch disc spline and main drive shaft
spline at the circumference of the clutch disc. If it is outside the
specified range, replace clutch disc and clutch cover as a set.

Using calipers, measure the depth to the clutch disc facing rivet
heads. If it exceeds the allowable wear limit, replace clutch disc
and clutch cover as a set.
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.

Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch disc and clutch cover as a set.
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 disc and clutch cover
as a set.
INSTALLATION
1. Apply recommended grease to clutch disc and main drive gear spline.
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 body, it cause clutch fluid leakage. Wipe off excess grease. Wipe off any grease oozing from
the parts.Runout limit/diameter of the area to be measured
: 1.0 mm (0.039 in)/230 mm (9.06 in) dia.
Maximum backlash of spline
: 1.0 mm (0.039 in)
SCL221
Facing wear limit (depth to the rivet head)
: 0.3 mm (0.012 in)
SCL229
Tolerance for diaphragm spring lever unevenness
: 0.8 mm (0.031 in)
Tool number : ST20050240 ( — )
SCIA6796E

CL-18
CLUTCH DISC, CLUTCH COVER
Revision: 2006 November2007 350Z
2. Install clutch disc and clutch cover. Pre-tighten mounting bolts
and install clutch aligning bar.
CAUTION:
If either clutch disk or clutch cover is needed to be
replaced, replace them as a set.
3. Tighten clutch cover mounting bolts evenly in two steps in the
order shown in the figure. Refer to CL-16, "
Removal and Instal-
lation" .
4. Install transmission assembly. Refer to MT-18, "
Removal and
Installation" . Tool number : ST20670000 ( — )
SCIA6797E