clutch NISSAN PICK-UP 1998 Repair Manual

GENERAL INFORMATIONGI
MAINTENANCEMA
ENGINE MECHANICALEM
ENGINE LUBRICATION &
COOLING SYSTEMSLC
ENGINE CONTROL SYSTEMEC
ACCELERATOR CONTROL, FUEL &
EXHAUST SYSTEMSFE
CLUTCHCL
MANUAL TRANSAXLEMT
TRANSFERTF
PROPELLER SHAFT &
DIFFERENTIAL CARRIERPD
FRONT AXLE & FRONT SUSPENSIONFA
REAR AXLE & REAR SUSPENSIONRA
BRAKE SYSTEMBR
STEERING SYSTEMST
RESTRAINT SYSTEMRS
BODY & TRIMBT
HEATER & AIR CONDITIONERHA
ELECTRICAL SYSTEMEL
ALPHABETICAL INDEXIDX
PICKUP
MODEL D22 SERIES
Edition: February 1998
Printing: May 1998 (01)
Publication No.: SM8E-0D22E0E
NISSAN EUROPE S.A.S.
1998 NISSAN EUROPE S.A.S. Printed in the Netherlands
Not to be reproduced in whole or in part without the prior written permission of Nissan Europe S.A.S., Paris, France.
QUICK REFERENCE INDEX

Note: ABS may operate and cause vibration under any of the
following conditions.
lApplying brake gradually when shifting or operating
clutch.
lLow friction (slippery) road.
lHigh speed cornering.
lDriving over bumps and pot holes.
lEngine speed is over 5,000 rpm with vehicle stopped.
Diagnostic Procedure 12 (Warning lamp does
not come on when ignition switch is turned
ON.)
CHECK FUSE.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Check 10A fuse . For fuse layout, refer to
POWER SUPPLY ROUTING in EL sec-
tion.
OK
cNG
Replace fuse.
CHECK WARNING LAMP ACTIVATE.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Disconnect ABS actuator and electric unit
connector.
Does the warning lamp activate?
No
cYes
VA(Go to next page.)
CHECK HARNESS FOR SHORT.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1. Disconnect ABS actuator and electric
unit connector.
2. Check voltage between ABS actuator
and electric unit connector
E4(body
side) terminal
V10(2WD) orV21(4WD)
and ground.
Battery voltage should not exist.
OK
cNG
Repair harness or connec-
tor.
CHECK COMBINATION METER.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Check combination meter. Refer to
WARNING LAMPS in EL section.
SBR063E
SBR069E
SBR144E
.
.
.
TROUBLE DIAGNOSES FOR SYMPTOMS
Diagnostic Procedure 11
(Pedal vibration and noise) (Cont'd)
BR-75

CLUTCH
SECTIONCL
CONTENTS
PRECAUTIONS AND PREPARATION..................... 1
Precautions ............................................................ 1
Special Service Tools ............................................ 1
Commercial Service Tools ..................................... 2
CLUTCH SYSTEM..................................................... 3
Clutch Pedal........................................................... 4
INSPECTION AND ADJUSTMENT........................... 5
Adjusting Clutch Pedal........................................... 5
Air Bleeding Procedure .......................................... 5
HYDRAULIC CLUTCH CONTROL........................... 6Clutch Master Cylinder .......................................... 6
Operating Cylinder ................................................. 8
CLUTCH RELEASE MECHANISM........................... 9
CLUTCH DISC AND CLUTCH COVER.................. 12
Clutch Disc and Flywheel .................................... 12
Clutch Cover ........................................................ 13
SERVICE DATA AND SPECIFICATIONS (SDS)... 14
General Specifications ......................................... 14
Inspection and Adjustment .................................. 14
CL

Precautions
lRecommended fluid is brake fluid ``DOT 3'' or ``DOT 4''.
Refer to MA section (``Fluids and Lubricants'', ``RECOM-
MENDED FLUIDS AND LUBRICANTS'').
lDo not reuse drained brake fluid.
lBe careful not to splash brake fluid on painted areas.
lWhen removing and installing clutch piping, use Tool.
lUse new brake fluid to clean or wash all parts of master
cylinder, operating cylinder and clutch damper.
lNever use mineral oils such as gasoline or kerosene. It
will ruin the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do
not use compressed air.
Special Service Tools
Tool number
Tool nameDescription
ST20050010
Base plate
NT403
Inspecting diaphragm spring of clutch cover
a: 357 mm (14.06 in) dia.
b: 43 mm (1.69 in)
ST20050100
Distance piece
NT402
Inspecting diaphragm spring of clutch cover
a: 25 mm (0.98 in) dia.
b: 7.8 mm (0.307 in)
GG94310000
Flare nut torque wrench
NT406
Removing and installing each clutch piping
a: 10 mm (0.39 in)
: 16.2 Nzm (1.65 kg-m, 11.9 ft-lb)
ST20600000
Clutch aligning bar
NT405
Installing clutch cover and clutch disc
a: 16.0 mm (0.630 in) dia.
b: 22.8 mm (0.898 in) dia.
c: 55 mm (2.17 in)
ST20050240
Diaphragm spring
adjusting wrench
NT404
Adjusting unevenness of clutch cover dia-
phragm spring
a: 150 mm (5.91 in)
b: 25 mm (0.98 in)
SBR820BA
PRECAUTIONS AND PREPARATION
CL-1

Commercial Service Tools
Tool name Description
V1Flare nut crowfoot
V2Torque wrench
NT684
Removing and installing clutch piping
a: 10 mm (0.39 in)
Bearing puller
NT077
Removing release bearing
Bearing drift
NT474
Installing release bearing
a: 52 mm (2.05 in) dia.
b: 45 mm (1.77 in) dia.
PRECAUTIONS AND PREPARATION
CL-2

SCL795
.2WD models with KA24E
engine
.2WD models with TD25 engine.4WD models with KA24E engine
CLUTCH SYSTEM
CL-3

Clutch Pedal
SCL741-N
.(KA24E engine).(TD25 engine)
CLUTCH SYSTEM
CL-4

Adjusting Clutch Pedal
1. Adjust pedal height with pedal stopper.
2. Adjust pedal free play with push rod.
Air Bleeding Procedure
Bleed air according to the following procedure.
Bleed the air from the master cylinder (RHD models only)
and then the operating cylinder.
1. Fill the master cylinder reservoir tank with new brake fluid.
2. Connect a transparent vinyl hose to the air bleeder.
3. Slowly depress the clutch pedal to its full stroke length and
release it completely. Repeat this operation several times at
2 to 3 second intervals.
4. Open the air bleeder with the clutch pedal fully depressed.
5. Close the air bleeder.
6. Release the clutch pedal and wait at least 5 seconds.
7. Repeat steps 3 through 6 above until air bubbles no longer
appear in the brake fluid.
SCL742-A
.LHD model
221 - 231 mm (8.70 - 0.09 in)
RHD model
195 - 205 mm (7.68 - 8.07 in)
Pedal free play ``A'':
1 - 1.5 mm (0.039 - 0.059 in)
SCL203
INSPECTION AND ADJUSTMENT
CL-5

Clutch Master Cylinder
DISASSEMBLY AND ASSEMBLY
lUse a screwdriver to remove stopper ring while pushing push
rod into cylinder.
lWhen installing stopper ring, tap in lightly while pushing push
rod into cylinder.
SCL743-A
.Clutch damper
SCL744
HYDRAULIC CLUTCH CONTROL
CL-6

INSPECTION
Check the following items, and replace as necessary.
lRubbing surface of cylinder and piston, for uneven wear, rust
or damage
lPiston with piston cup, for wear or damage
lReturn spring, for wear or damage
lDust cover, for cracks, deformation or damage
lReservoir, for deformation or damage
HYDRAULIC CLUTCH CONTROL
Clutch Master Cylinder (Cont'd)
CL-7