NISSAN NAVARA 2005 Repair Workshop Manual

CLUTCH PEDAL
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Removal and InstallationECS00ICH
COMPONENTS
REMOVAL
1. Disconnect clutch interlock switch and ASCD clutch switch (with ASCD) harness connectors.
2. Remove snap pin and clevis pin from clevis of clutch master cylinder.
3. Remove clutch pedal assembly mounting nuts and bolt, and then remove clutch pedal assembly from the
vehicle.
INSPECTION AFTER REMOVAL
lCheck clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace clutch pedal.
lCheck assist spring for settling. If settling is found, replace assist spring.
INSTALLATION
Installation is the reverse order of removal.
NOTE:
Tighten pedal stopper bolt lock nut or ASCD clutch switch lock nut to the specified torque after installing clutch
pedal assembly in vehicle and adjusting the pedal free play.
1. Clutch pedal assembly 2. Clevis pin 3. Bushing
4. Stopper rubber 5. Pedal stopper bolt (Without ASCD) 6. ASCD clutch switch (With ASCD)
7. Pedal pad 8. Stopper rubber 9. Snap pin
10. Clutch interlock switch 11. Bushing 12. Assist spring
PCIB1387E

CL-8
CLUTCH FLUID
CLUTCH FLUID
PFP:00017
Air Bleeding ProcedureECS00ICI
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.
CAUTION:
lMonitor clutch fluid level in reservoir tank to make sure it
does not empty.
lKeep 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.
lFor RHD models: Bleed air for operating cylinder.
lFor LHD models: Bleed air for clutch connector first, and then for
operating cylinder.
1. Fill reservoir tank with new clutch fluid.
2. Connect a transparent vinyl hose to air bleeder valve.
3. Depress clutch pedal slowly and fully several times at an interval
of 2 to 3 seconds and hold it.
4. With clutch pedal depressed, open air bleeder valve to release
air.
5. Close air bleeder valve.
6. Release clutch pedal and wait for 5 seconds.
7. Repeat steps 3 to 6 until no bubbles can be observed in clutch
fluid.
8. Tighten air bleeder valve to the specified torque. Refer toCL-11,
"Components"andCL-13, "Removal and Installation".
PCIB1601E
PCIB1390E

CLUTCH MASTER CYLINDER
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CLUTCH MASTER CYLINDERPFP:30610
ComponentsECS00ICJ
Removal and InstallationECS00ICK
REMOVAL
1. Using one of the following methods, remove hose from nipple.
lDrain clutch fluid from reservoir tank and then remove hose.
lRemove hose from nipple. Immediately plug hose and reservoir tank to prevent clutch fluid from drip-
ping.
CAUTION:
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.
2. Remove clutch tube using a flare nut wrench.
3. Remove snap pin and clevis pin on clevis in passenger compartment to separate clutch pedal.
4. Remove master cylinder assembly mounting nuts, and then remove master cylinder assembly from the
vehicle.
INSTALLATION
1. Check position of clevis and push rod. If measurement is outside
the standard length, adjust position of clevis and push rod.
2. Connect clutch tube to master cylinder assembly and tempo-
rarily tighten flare nut.
3. Install master cylinder assembly and tighten mounting nuts to
the specified torque. Refer toCL-9, "
Components".
4. Tightenclutchtubeflarenuttothespecifiedtorqueusingaflare
nut torque wrench. Refer toCL-13, "
Removal and Installation".
5. Set clevis to clutch pedal and insert clevis pin.
1. Nipple 2. Clamp 3. Hose
4. Cylinder body 5. Dust cover 6. Clevis
7. Clevis pin 8. Snap pin 9. Stopper ring
10. Stopper 11. Push rod 12. Piston assembly
13. Return spring 14. Seal 15. Spring pin
PCIB1388E
Length “L”
RHD models : 111.0 mm (4.37 in)
LHD models : 120.5 mm (4.74 in)
SCIA5158E

CL-10
CLUTCH MASTER CYLINDER
6. Attach snap pin to clevis pin.
7. Install hose to nipple.
8. After completing this procedure, inspect and adjust for clutch pedal and then bleed the air from the clutch
hydraulic system. Refer toCL-6, "
On-Vehicle Inspection and Adjustment"andCL-8, "Air Bleeding Proce-
dure".
Disassembly and AssemblyECS00ICL
DISASSEMBLY
1. Remove spring pin using a pin punch.
2. Remove nipple and seal from cylinder body.
3. Loosen push rod lock nut then remove clevis and lock nut, if
necessary.
NOTE:
Clutch pedal height is controlled with position of clevis and push
rod.
4. Remove dust cover from cylinder body.
5. Remove stopper ring and stopper. Remove push rod from cylin-
der body while holding it securely to prevent piston assembly
popping out.
6. Remove piston assembly and return spring.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.
lDamaged cylinder internal wall, foreign matter, wear, corrosion, or pinhole
lDamaged or deformed nipple or reservoir tank
lSettling of return spring
lCracked or deformed dust cover
ASSEMBLY
1. Apply rubber lubricant to the internal surface of cylinder body, the sliding surface of piston assembly, and
piston cup. Insert return spring and piston assembly to cylinder body.
2. Apply silicon grease to push rod and install stopper. Install stopper ring while holding down push rod by
hand to prevent piston assembly from popping out.
3. Install dust cover to cylinder body.
4. Install seal and nipple to cylinder body.
5. Install spring pin using a pin punch.
6. Install clevis to push rod.
7. Check and adjust the positions of clevis and push rod. After
adjusting “L”, tighten lock nut to the specified torque. Refer to
CL-9, "
Components".
PCIB0274E
Length “L”
RHD models : 111.0 mm (4.37 in)
LHD models : 120.5 mm (4.74 in)
SCIA5158E

OPERATING CYLINDER
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OPERATING CYLINDERPFP:30620
ComponentsECS00ICM
RHD models
LHD models
Removal and InstallationECS00ICN
REMOVAL
1. Drain clutch fluid.
PCIB1602E
1. Air bleeder valve 2. Copper washer 3. Clutch hose
4. Cylinder body 5. Dust cover 6. Push rod
7. Piston assembly 8. Piston cup 9. Piston spring
PCIB1606E
1. Air bleeder valve 2. Copper washer 3. Union bolt
4. Clutch hose 5. Cylinder body 6. Dust cover
7. Push rod 8. Piston assembly 9. Piston cup
10. Piston spring

CL-12
OPERATING CYLINDER
CAUTION:
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.
2. Remove clutch hose from operating cylinder assembly.
3. Remove operating cylinder assembly mounting bolts, and then remove operating cylinder assembly from
the vehicle.
INSTALLATION
Note the following, and install in the reverse order of removal.
lInstall clutch hose with care so that it will not be bent or twisted.
lTightenclutchhosetothespecifiedtorque.
CAUTION:
Do not reuse copper washer.
lAfter completing the procedure, bleed the air from the clutch hydraulic system. Refer toCL-8, "Air Bleed-
ing Procedure".
Disassembly and AssemblyECS00ICO
DISASSEMBLY
lRemove dust cover and push rod. Then remove piston, piston cup and piston spring from cylinder body.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.
lDamage to cylinder internal surface or piston sliding surface. Foreign matter, wear, corrosion, or pinhole
lSettling of piston spring
lCracked or deformed dust cover
ASSEMBLY
1. Apply rubber lubricant to cylinder body internal surface and rubber grease to piston cup and piston. Insert
piston assembly and piston spring into cylinder body.
2. Apply rubber grease to dust cover and then install push rod and dust cover.

CLUTCH PIPING
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CLUTCH PIPINGPFP:30650
Removal and InstallationECS00ICP
RHD models
LHD models
Carefully observe the following steps during clutch tube removal and installation.
CAUTION:
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.
lTo fix clutch hose on bracket, position clutch hose clasp on the
emboss of bracket and drive lock plate vertically from above. Be
careful not to bend or twist clutch hose. Do not scratch or dam-
age clutch hose.
lTighten clutch tube flare nut to the specified torque.
lTighten clutch hose or union bolt to the specified torque.
CAUTION:
Do not reuse copper washer.
lAfter installation, bleed the air from the clutch hydraulic system.
Refer toCL-8, "
Air Bleeding Procedure".
PCIB1651E
1. Clutch tube 2. Clutch orifice 3. Lock plate
4. Clutch hose 5. Operating cylinder 6. Master cylinder
7. Clutch pedal
PCIB1605E
1. Clutch tube 2. Clutch orifice 3. Lock plate
4. Clutch hose 5. Operating cylinder 6. Clutch tube
7. Clutch connector 8. Air bleeder valve 9. Master cylinder
10. Clutch pedal
PCIB0681E

CL-14
CLUTCH RELEASE MECHANISM
CLUTCH RELEASE MECHANISM
PFP:30502
Removal and InstallationECS00ICQ
COMPONENTS
REMOVAL
1. Remove manual transmission from the vehicle. Refer toMT-16, "Removal and Installation from Vehicle".
2. Remove release bearing sleeve assembly, holder spring and withdrawal lever from inside clutch housing.
3. Remove dust cover.
4. Remove snap spring from withdrawal lever.
5. Remove release bearing from release bearing sleeve using a
puller.
1. Holder spring 2. Release bearing sleeve 3. Release bearing
4. Snap spring 5. Dust cover 6. Withdrawal lever
PCIB1615E
CLA0013D

CLUTCH RELEASE MECHANISM
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INSPECTION AFTER REMOVAL
lIf release bearing is seized, damaged, not properly centered or
does not rotate smoothly, replace it.
lIf contact surface of withdrawal lever is excessively worn,
replace it.
lIf dust cover is cracked, replace it.
INSTALLATION
CAUTION:
lBe 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. Wipe off any grease oozing
from the parts.
lBe careful not to bring any grease to the clutch disk facing, pressure plate surface and flywheel
surface.
1. Install release bearing to release bearing sleeve using the drift.
CAUTION:
Press bearing inner race by pushing with the drift.
2. Following the instructions below, apply grease to the specified points.
CAUTION:
Wipe off any old grease, debris, or powdery residue left on the grease applying surfaces.
lEvenly apply approximately 1 mm (0.04 in) thick coating of recommended grease to withdrawal lever
and release bearing sliding surface.
lApply recommended grease to withdrawal lever ball pin contact surface and inner slots of release bear-
ing sleeve. The grease surface should be level with the surrounding area.
lApply a thin coat of recommended grease evenly to release bearing sleeve sliding surface of front
cover. Install release bearing sleeve assembly to front cover. Wipe off any excess grease that oozes
from the parts and then remove release bearing sleeve assembly.
3. To install, reverse the removal procedure, following the cautions below.
CAUTION:
lBefore installing manual transmission to the vehicle, make sure that each sliding surface slides
smoothly by operating withdrawal lever.
SCIA1660E
Tool number : KV30101400
PCIB0275E
PCIB1393E

CL-16
CLUTCH RELEASE MECHANISM
lWhen assembling, make sure that both ends of snap
spring touch the end face of withdrawal lever.
lBe careful with the orientation snap spring.
SCIA6903E